Surgical instrument with variable duration trigger arrangement

ABSTRACT

A motorized surgical instrument is disclosed. The surgical instrument includes a displacement member, a motor coupled to displacement member, a control circuit coupled to the motor, a parameter sensor coupled to the control circuit and a position sensor coupled to the control circuit. The control circuit is configured to receive a parameter output of the parameter sensor indicative of a force applied to translate the displacement member, determine a duration during which the parameter output is maintained at or above a predetermined fault threshold, receive a position output of the position sensor indicative of at least one position of the displacement member during the duration, and effect a motor control action based on the duration and the at least one position.

TECHNICAL FIELD

The present disclosure relates to surgical instruments and, in variouscircumstances, to surgical stapling and cutting instruments and staplecartridges therefor that are designed to staple and cut tissue.

BACKGROUND

In a motorized surgical stapling and cutting instrument it may be usefulto control the velocity of a cutting member or to control thearticulation velocity of an end effector. Velocity of a displacementmember may be determined by measuring elapsed time at predeterminedposition intervals of the displacement member or measuring the positionof the displacement member at predetermined time intervals. The controlmay be open loop or closed loop. Such measurements may be useful toevaluate tissue conditions such as tissue thickness and adjust thevelocity of the cutting member during a firing stroke to account for thetissue conditions. Tissue thickness may be determined by comparingexpected velocity of the cutting member to the actual velocity of thecutting member. In some situations, it may be useful to articulate theend effector at a constant articulation velocity. In other situations,it may be useful to drive the end effector at a different articulationvelocity than a default articulation velocity at one or more regionswithin a sweep range of the end effector.

During use of a motorized surgical stapling and cutting instrument it ispossible that maximum current could be triggered by an instantaneousexceeding of a current limit during a predefined zone of a firing strokeof the cutting member or a closure stroke of an anvil. Nevertheless,outside of the predefined zone the current limit may be exceeded over apredefined period to minimize the likelihood that noise within ameasurement inadvertently triggers the that maximum current event.Therefore, it may be desirable to set a predefined time period for atriggering event to cause a motor control program to change based on thelocation of the cutting member or anvil within a firing stroke or aclosure stroke.

SUMMARY

In one aspect, a surgical instrument is provided. The surgicalinstrument comprising: a displacement member; a motor coupled todisplacement member, the motor operable to translate the displacementmember; a control circuit coupled to the motor; a parameter sensorcoupled to the control circuit; and a position sensor coupled to thecontrol circuit, wherein the control circuit is configured to: receive aparameter output of the parameter sensor indicative of a force appliedto translate the displacement member; determine a duration during whichthe parameter output is maintained at or above a predetermined faultthreshold; receive a position output of the position sensor indicativeof at least one position of the displacement member during the duration;and effect a motor control action based on the duration and the at leastone position.

In another aspect, the surgical instrument comprises a displacementmember; a motor coupled to the displacement member; a current sensorcoupled to the motor, the current sensor configured to measure currentdrawn by the motor while translating the displacement member; a positionsensor; and a control circuit coupled to the motor, the current sensor,and the position sensor, wherein the control circuit is configured to:determine a duration during which the current drawn by the motor ismaintained at or above a predetermined fault threshold; receive aposition output of the position sensor indicative of at least oneposition of the displacement member during the duration; and effect amotor control action based on the duration and the at least oneposition.

In another aspect, the a method of controlling a motor in a surgicalinstrument is provided, the surgical instrument comprising adisplacement member, a motor coupled to displacement member, the motoroperable to translate the displacement member, a control circuit coupledto the motor, a parameter sensor coupled to the control circuit, and aposition sensor coupled to the control circuit, the method comprising:receiving, by the control circuit, a parameter output of the parametersensor indicative of a force applied to translate the displacementmember; determining, by the control circuit, a duration during which theparameter output is maintained at or above a predetermined faultthreshold; receiving, by the control circuit, a position output of theposition sensor indicative of at least one position of the displacementmember during the duration; and effecting, by the control circuit, amotor control action based on the duration and the at least oneposition.

FIGURES

The novel features of the aspects described herein are set forth withparticularity in the appended claims. These aspects, however, both as toorganization and methods of operation may be better understood byreference to the following description, taken in conjunction with theaccompanying drawings.

FIG. 1 is a perspective view of a surgical instrument that has aninterchangeable shaft assembly operably coupled thereto according to oneaspect of this disclosure.

FIG. 2 is an exploded assembly view of a portion of the surgicalinstrument of FIG. 1 according to one aspect of this disclosure.

FIG. 3 is an exploded assembly view of portions of the interchangeableshaft assembly according to one aspect of this disclosure.

FIG. 4 is an exploded view of an end effector of the surgical instrumentof FIG. 1 according to one aspect of this disclosure.

FIGS. 5A-5B is a block diagram of a control circuit of the surgicalinstrument of FIG. 1 spanning two drawing sheets according to one aspectof this disclosure.

FIG. 6 is a block diagram of the control circuit of the surgicalinstrument of FIG. 1 illustrating interfaces between the handleassembly, the power assembly, and the handle assembly and theinterchangeable shaft assembly according to one aspect of thisdisclosure.

FIG. 7 illustrates a control circuit configured to control aspects ofthe surgical instrument of FIG. 1 according to one aspect of thisdisclosure.

FIG. 8 illustrates a combinational logic circuit configured to controlaspects of the surgical instrument of FIG. 1 according to one aspect ofthis disclosure.

FIG. 9 illustrates a sequential logic circuit configured to controlaspects of the surgical instrument of FIG. 1 according to one aspect ofthis disclosure.

FIG. 10 is a diagram of an absolute positioning system of the surgicalinstrument of FIG. 1 where the absolute positioning system comprises acontrolled motor drive circuit arrangement comprising a sensorarrangement according to one aspect of this disclosure.

FIG. 11 is an exploded perspective view of the sensor arrangement for anabsolute positioning system showing a control circuit board assembly andthe relative alignment of the elements of the sensor arrangementaccording to one aspect of this disclosure.

FIG. 12 is a diagram of a position sensor comprising a magnetic rotaryabsolute positioning system according to one aspect of this disclosure.

FIG. 13 is a section view of an end effector of the surgical instrumentof FIG. 1 showing a firing member stroke relative to tissue graspedwithin the end effector according to one aspect of this disclosure.

FIG. 14 illustrates a block diagram of a surgical instrument programmedto control distal translation of a displacement member according to oneaspect of this disclosure.

FIG. 15 illustrates a diagram plotting two example displacement memberstrokes executed according to one aspect of this disclosure.

FIG. 16 is a diagram of current (I) drawn by a motor to translate anI-beam of the surgical instrument of FIG. 1 in a firing stroke, whichrepresents the force to fire (FTF) the surgical instrument, as afunction of the distance traveled by the I-beam during the firing strokeaccording to one aspect of this disclosure.

FIG. 17 is a logic flow diagram of a process depicting a control programor logic configuration representing a firing control program accordingto one aspect of this disclosure.

FIG. 18 is a logic flow diagram of a process depicting a control programor logic configuration representing a firing control program accordingto one aspect of this disclosure.

FIG. 19 is a logic flow diagram of a process depicting a control programor logic configuration representing a firing control program accordingto one aspect of this disclosure.

DESCRIPTION

Applicant of the present application owns the following patentapplications filed concurrently herewith and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/627,998, titled CONTROL OF MOTORVELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENT BASED ON ANGLE OFARTICULATION, by inventors Frederick E. Shelton, IV et al., filed Jun.20, 2017.

U.S. patent application Ser. No. 15/628,036, titled SYSTEMS AND METHODSFOR CONTROLLING DISPLACEMENT MEMBER MOTION OF A SURGICAL STAPLING ANDCUTTING INSTRUMENT, by inventors Frederick E. Shelton, IV et al., filedJun. 20, 2017.

U.S. patent application Ser. No. 15/628,050, titled SYSTEMS AND METHODSFOR CONTROLLING MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTINGINSTRUMENT ACCORDING TO ARTICULATION ANGLE OF END EFFECTOR, by inventorsFrederick E. Shelton, IV et al., filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,075, titled SYSTEMS AND METHODSFOR CONTROLLING MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTINGINSTRUMENT, by inventors Frederick E. Shelton, IV et al., filed Jun. 20,2017.

U.S. patent application Ser. No. 15/628,154, titled SURGICAL INSTRUMENTHAVING CONTROLLABLE ARTICULATION VELOCITY, by inventors Frederick E.Shelton, IV et al., filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,158, titled SYSTEMS AND METHODSFOR CONTROLLING VELOCITY OF A DISPLACEMENT MEMBER OF A SURGICAL STAPLINGAND CUTTING INSTRUMENT, by inventors Frederick E. Shelton, IV et al.,filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,162, titled SYSTEMS AND METHODSFOR CONTROLLING DISPLACEMENT MEMBER VELOCITY FOR A SURGICAL INSTRUMENT,by inventors Frederick E. Shelton, IV et al., filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,168, titled CONTROL OF MOTORVELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENT BASED ON ANGLE OFARTICULATION, by inventors Frederick E. Shelton, IV et al., filed Jun.20, 2017.

U.S. patent application Ser. No. 15/628,175, titled TECHNIQUES FORADAPTIVE CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTINGINSTRUMENT, by inventors Frederick E. Shelton, IV et al., filed Jun. 20,2017.

U.S. patent application Ser. No. 15/628,045, titled TECHNIQUES FORCLOSED LOOP CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTINGINSTRUMENT, by inventors Raymond E. Parfett et al., filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,053, titled CLOSED LOOP FEEDBACKCONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENTBASED ON MAGNITUDE OF VELOCITY ERROR MEASUREMENTS, by inventors RaymondE. Parfett et al., filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,060, titled CLOSED LOOP FEEDBACKCONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENTBASED ON MEASURED TIME OVER A SPECIFIED DISPLACEMENT DISTANCE, byinventors Jason L. Harris et al., filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,067, titled CLOSED LOOP FEEDBACKCONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENTBASED ON MEASURED DISPLACEMENT DISTANCE TRAVELED OVER A SPECIFIED TIMEINTERVAL, by inventors Frederick E. Shelton, IV et al., filed Jun. 20,2017.

U.S. patent application Ser. No. 15/628,072, titled CLOSED LOOP FEEDBACKCONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENTBASED ON MEASURED TIME OVER A SPECIFIED NUMBER OF SHAFT ROTATIONS, byinventors Frederick E. Shelton, IV et al., filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,029, titled SYSTEMS AND METHODSFOR CONTROLLING DISPLAYING MOTOR VELOCITY FOR A SURGICAL INSTRUMENT, byinventors Jason L. Harris et al., filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,077, titled SYSTEMS AND METHODSFOR CONTROLLING MOTOR SPEED ACCORDING TO USER INPUT FOR A SURGICALINSTRUMENT, by inventors Jason L. Harris et al., filed Jun. 20, 2017.

U.S. patent application Ser. No. 15/628,115, titled CLOSED LOOP FEEDBACKCONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENTBASED ON SYSTEM CONDITIONS, by inventors Frederick E. Shelton, IV etal., filed Jun. 20, 2017.

Applicant of the present application owns the following U.S. DesignPatent Applications filed concurrently herewith and which are eachherein incorporated by reference in their respective entireties:

U.S. Des. patent application Ser. No. 29/608,238, titled GRAPHICAL USERINTERFACE FOR A DISPLAY OR PORTION THEREOF, by inventors Jason L. Harriset al., filed Jun. 20, 2017.

U.S. Des. patent application Ser. No. 29/608,231, titled GRAPHICAL USERINTERFACE FOR A DISPLAY OR PORTION THEREOF, by inventors Jason L. Harriset al., filed Jun. 20, 2017.

U.S. Des. patent application Ser. No. 29/608,246, titled GRAPHICAL USERINTERFACE FOR A DISPLAY OR PORTION THEREOF, by inventors Frederick E.Shelton, IV et al., filed Jun. 20, 2017.

Certain aspects are shown and described to provide an understanding ofthe structure, function, manufacture, and use of the disclosed devicesand methods. Features shown or described in one example may be combinedwith features of other examples and modifications and variations arewithin the scope of this disclosure.

The terms “proximal” and “distal” are relative to a clinicianmanipulating the handle of the surgical instrument where “proximal”refers to the portion closer to the clinician and “distal” refers to theportion located further from the clinician. For expediency, spatialterms “vertical,” “horizontal,” “up,” and “down” used with respect tothe drawings are not intended to be limiting and/or absolute, becausesurgical instruments can used in many orientations and positions.

Example devices and methods are provided for performing laparoscopic andminimally invasive surgical procedures. Such devices and methods,however, can be used in other surgical procedures and applicationsincluding open surgical procedures, for example. The surgicalinstruments can be inserted into a through a natural orifice or throughan incision or puncture hole formed in tissue. The working portions orend effector portions of the instruments can be inserted directly intothe body or through an access device that has a working channel throughwhich the end effector and elongated shaft of the surgical instrumentcan be advanced.

FIGS. 1-4 depict a motor-driven surgical instrument 10 for cutting andfastening that may or may not be reused. In the illustrated examples,the surgical instrument 10 includes a housing 12 that comprises a handleassembly 14 that is configured to be grasped, manipulated, and actuatedby the clinician. The housing 12 is configured for operable attachmentto an interchangeable shaft assembly 200 that has an end effector 300operably coupled thereto that is configured to perform one or moresurgical tasks or procedures. In accordance with the present disclosure,various forms of interchangeable shaft assemblies may be effectivelyemployed in connection with robotically controlled surgical systems. Theterm “housing” may encompass a housing or similar portion of a roboticsystem that houses or otherwise operably supports at least one drivesystem configured to generate and apply at least one control motion thatcould be used to actuate interchangeable shaft assemblies. The term“frame” may refer to a portion of a handheld surgical instrument. Theterm “frame” also may represent a portion of a robotically controlledsurgical instrument and/or a portion of the robotic system that may beused to operably control a surgical instrument. Interchangeable shaftassemblies may be employed with various robotic systems, instruments,components, and methods disclosed in U.S. Pat. No. 9,072,535, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, which is herein incorporated by reference in its entirety.

FIG. 1 is a perspective view of a surgical instrument 10 that has aninterchangeable shaft assembly 200 operably coupled thereto according toone aspect of this disclosure. The housing 12 includes an end effector300 that comprises a surgical cutting and fastening device configured tooperably support a surgical staple cartridge 304 therein. The housing 12may be configured for use in connection with interchangeable shaftassemblies that include end effectors that are adapted to supportdifferent sizes and types of staple cartridges, have different shaftlengths, sizes, and types. The housing 12 may be employed with a varietyof interchangeable shaft assemblies, including assemblies configured toapply other motions and forms of energy such as, radio frequency (RF)energy, ultrasonic energy, and/or motion to end effector arrangementsadapted for use in connection with various surgical applications andprocedures. The end effectors, shaft assemblies, handles, surgicalinstruments, and/or surgical instrument systems can utilize any suitablefastener, or fasteners, to fasten tissue. For instance, a fastenercartridge comprising a plurality of fasteners removably stored thereincan be removably inserted into and/or attached to the end effector of ashaft assembly.

The handle assembly 14 may comprise a pair of interconnectable handlehousing segments 16, 18 interconnected by screws, snap features,adhesive, etc. The handle housing segments 16, 18 cooperate to form apistol grip portion 19 that can be gripped and manipulated by theclinician. The handle assembly 14 operably supports a plurality of drivesystems configured to generate and apply control motions tocorresponding portions of the interchangeable shaft assembly that isoperably attached thereto. A display may be provided below a cover 45.

FIG. 2 is an exploded assembly view of a portion of the surgicalinstrument 10 of FIG. 1 according to one aspect of this disclosure. Thehandle assembly 14 may include a frame 20 that operably supports aplurality of drive systems. The frame 20 can operably support a “first”or closure drive system 30, which can apply closing and opening motionsto the interchangeable shaft assembly 200. The closure drive system 30may include an actuator such as a closure trigger 32 pivotally supportedby the frame 20. The closure trigger 32 is pivotally coupled to thehandle assembly 14 by a pivot pin 33 to enable the closure trigger 32 tobe manipulated by a clinician. When the clinician grips the pistol gripportion 19 of the handle assembly 14, the closure trigger 32 can pivotfrom a starting or “unactuated” position to an “actuated” position andmore particularly to a fully compressed or fully actuated position.

The handle assembly 14 and the frame 20 may operably support a firingdrive system 80 configured to apply firing motions to correspondingportions of the interchangeable shaft assembly attached thereto. Thefiring drive system 80 may employ an electric motor 82 located in thepistol grip portion 19 of the handle assembly 14. The electric motor 82may be a DC brushed motor having a maximum rotational speed ofapproximately 25,000 RPM, for example. In other arrangements, the motormay include a brushless motor, a cordless motor, a synchronous motor, astepper motor, or any other suitable electric motor. The electric motor82 may be powered by a power source 90 that may comprise a removablepower pack 92. The removable power pack 92 may comprise a proximalhousing portion 94 configured to attach to a distal housing portion 96.The proximal housing portion 94 and the distal housing portion 96 areconfigured to operably support a plurality of batteries 98 therein.Batteries 98 may each comprise, for example, a Lithium Ion (LI) or othersuitable battery. The distal housing portion 96 is configured forremovable operable attachment to a control circuit board 100, which isoperably coupled to the electric motor 82. Several batteries 98connected in series may power the surgical instrument 10. The powersource 90 may be replaceable and/or rechargeable. A display 43, which islocated below the cover 45, is electrically coupled to the controlcircuit board 100. The cover 45 may be removed to expose the display 43.

The electric motor 82 can include a rotatable shaft (not shown) thatoperably interfaces with a gear reducer assembly 84 mounted in meshingengagement with a with a set, or rack, of drive teeth 122 on alongitudinally movable drive member 120. The longitudinally movabledrive member 120 has a rack of drive teeth 122 formed thereon formeshing engagement with a corresponding drive gear 86 of the gearreducer assembly 84.

In use, a voltage polarity provided by the power source 90 can operatethe electric motor 82 in a clockwise direction wherein the voltagepolarity applied to the electric motor by the battery can be reversed inorder to operate the electric motor 82 in a counter-clockwise direction.When the electric motor 82 is rotated in one direction, thelongitudinally movable drive member 120 will be axially driven in thedistal direction “DD.” When the electric motor 82 is driven in theopposite rotary direction, the longitudinally movable drive member 120will be axially driven in a proximal direction “PD.” The handle assembly14 can include a switch that can be configured to reverse the polarityapplied to the electric motor 82 by the power source 90. The handleassembly 14 may include a sensor configured to detect the position ofthe longitudinally movable drive member 120 and/or the direction inwhich the longitudinally movable drive member 120 is being moved.

Actuation of the electric motor 82 can be controlled by a firing trigger130 that is pivotally supported on the handle assembly 14. The firingtrigger 130 may be pivoted between an unactuated position and anactuated position.

Turning back to FIG. 1, the interchangeable shaft assembly 200 includesan end effector 300 comprising an elongated channel 302 configured tooperably support a surgical staple cartridge 304 therein. The endeffector 300 may include an anvil 306 that is pivotally supportedrelative to the elongated channel 302. The interchangeable shaftassembly 200 may include an articulation joint 270. Construction andoperation of the end effector 300 and the articulation joint 270 are setforth in U.S. Patent Application Publication No. 2014/0263541, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, whichis herein incorporated by reference in its entirety. The interchangeableshaft assembly 200 may include a proximal housing or nozzle 201comprised of nozzle portions 202, 203. The interchangeable shaftassembly 200 may include a closure tube 260 extending along a shaft axisSA that can be utilized to close and/or open the anvil 306 of the endeffector 300.

Turning back to FIG. 1, the closure tube 260 is translated distally(direction “DD”) to close the anvil 306, for example, in response to theactuation of the closure trigger 32 in the manner described in theaforementioned reference U.S. Patent Application Publication No.2014/0263541. The anvil 306 is opened by proximally translating theclosure tube 260. In the anvil-open position, the closure tube 260 ismoved to its proximal position.

FIG. 3 is another exploded assembly view of portions of theinterchangeable shaft assembly 200 according to one aspect of thisdisclosure. The interchangeable shaft assembly 200 may include a firingmember 220 supported for axial travel within the spine 210. The firingmember 220 includes an intermediate firing shaft 222 configured toattach to a distal cutting portion or knife bar 280. The firing member220 may be referred to as a “second shaft” or a “second shaft assembly”.The intermediate firing shaft 222 may include a longitudinal slot 223 ina distal end configured to receive a tab 284 on the proximal end 282 ofthe knife bar 280. The longitudinal slot 223 and the proximal end 282may be configured to permit relative movement there between and cancomprise a slip joint 286. The slip joint 286 can permit theintermediate firing shaft 222 of the firing member 220 to articulate theend effector 300 about the articulation joint 270 without moving, or atleast substantially moving, the knife bar 280. Once the end effector 300has been suitably oriented, the intermediate firing shaft 222 can beadvanced distally until a proximal sidewall of the longitudinal slot 223contacts the tab 284 to advance the knife bar 280 and fire the staplecartridge positioned within the channel 302. The spine 210 has anelongated opening or window 213 therein to facilitate assembly andinsertion of the intermediate firing shaft 222 into the spine 210. Oncethe intermediate firing shaft 222 has been inserted therein, a top framesegment 215 may be engaged with the shaft frame 212 to enclose theintermediate firing shaft 222 and knife bar 280 therein. Operation ofthe firing member 220 may be found in U.S. Patent ApplicationPublication No. 2014/0263541. A spine 210 can be configured to slidablysupport a firing member 220 and the closure tube 260 that extends aroundthe spine 210. The spine 210 may slidably support an articulation driver230.

The interchangeable shaft assembly 200 can include a clutch assembly 400configured to selectively and releasably couple the articulation driver230 to the firing member 220. The clutch assembly 400 includes a lockcollar, or lock sleeve 402, positioned around the firing member 220wherein the lock sleeve 402 can be rotated between an engaged positionin which the lock sleeve 402 couples the articulation driver 230 to thefiring member 220 and a disengaged position in which the articulationdriver 230 is not operably coupled to the firing member 220. When thelock sleeve 402 is in the engaged position, distal movement of thefiring member 220 can move the articulation driver 230 distally and,correspondingly, proximal movement of the firing member 220 can move thearticulation driver 230 proximally. When the lock sleeve 402 is in thedisengaged position, movement of the firing member 220 is nottransmitted to the articulation driver 230 and, as a result, the firingmember 220 can move independently of the articulation driver 230. Thenozzle 201 may be employed to operably engage and disengage thearticulation drive system with the firing drive system in the variousmanners described in U.S. Patent Application Publication No.2014/0263541.

The interchangeable shaft assembly 200 can comprise a slip ring assembly600 which can be configured to conduct electrical power to and/or fromthe end effector 300 and/or communicate signals to and/or from the endeffector 300, for example. The slip ring assembly 600 can comprise aproximal connector flange 604 and a distal connector flange 601positioned within a slot defined in the nozzle portions 202, 203. Theproximal connector flange 604 can comprise a first face and the distalconnector flange 601 can comprise a second face positioned adjacent toand movable relative to the first face. The distal connector flange 601can rotate relative to the proximal connector flange 604 about the shaftaxis SA-SA (FIG. 1). The proximal connector flange 604 can comprise aplurality of concentric, or at least substantially concentric,conductors 602 defined in the first face thereof. A connector 607 can bemounted on the proximal side of the distal connector flange 601 and mayhave a plurality of contacts wherein each contact corresponds to and isin electrical contact with one of the conductors 602. Such anarrangement permits relative rotation between the proximal connectorflange 604 and the distal connector flange 601 while maintainingelectrical contact there between. The proximal connector flange 604 caninclude an electrical connector 606 that can place the conductors 602 insignal communication with a shaft circuit board, for example. In atleast one instance, a wiring harness comprising a plurality ofconductors can extend between the electrical connector 606 and the shaftcircuit board. The electrical connector 606 may extend proximallythrough a connector opening defined in the chassis mounting flange. U.S.Patent Application Publication No. 2014/0263551, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, is incorporated herein byreference in its entirety. U.S. Patent Application Publication No.2014/0263552, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM,is incorporated by reference in its entirety. Further details regardingslip ring assembly 600 may be found in U.S. Patent ApplicationPublication No. 2014/0263541.

The interchangeable shaft assembly 200 can include a proximal portionfixably mounted to the handle assembly 14 and a distal portion that isrotatable about a longitudinal axis. The rotatable distal shaft portioncan be rotated relative to the proximal portion about the slip ringassembly 600. The distal connector flange 601 of the slip ring assembly600 can be positioned within the rotatable distal shaft portion.

FIG. 4 is an exploded view of one aspect of an end effector 300 of thesurgical instrument 10 of FIG. 1 according to one aspect of thisdisclosure. The end effector 300 may include the anvil 306 and thesurgical staple cartridge 304. The anvil 306 may be coupled to anelongated channel 302. Apertures 199 can be defined in the elongatedchannel 302 to receive pins 152 extending from the anvil 306 to allowthe anvil 306 to pivot from an open position to a closed positionrelative to the elongated channel 302 and surgical staple cartridge 304.A firing bar 172 is configured to longitudinally translate into the endeffector 300. The firing bar 172 may be constructed from one solidsection, or may include a laminate material comprising a stack of steelplates. The firing bar 172 comprises an I-beam 178 and a cutting edge182 at a distal end thereof. A distally projecting end of the firing bar172 can be attached to the I-beam 178 to assist in spacing the anvil 306from a surgical staple cartridge 304 positioned in the elongated channel302 when the anvil 306 is in a closed position. The I-beam 178 mayinclude a sharpened cutting edge 182 to sever tissue as the I-beam 178is advanced distally by the firing bar 172. In operation, the I-beam 178may, or fire, the surgical staple cartridge 304. The surgical staplecartridge 304 can include a molded cartridge body 194 that holds aplurality of staples 191 resting upon staple drivers 192 withinrespective upwardly open staple cavities 195. A wedge sled 190 is drivendistally by the I-beam 178, sliding upon a cartridge tray 196 of thesurgical staple cartridge 304. The wedge sled 190 upwardly cams thestaple drivers 192 to force out the staples 191 into deforming contactwith the anvil 306 while the cutting edge 182 of the I-beam 178 seversclamped tissue.

The I-beam 178 can include upper pins 180 that engage the anvil 306during firing. The I-beam 178 may include middle pins 184 and a bottomfoot 186 to engage portions of the cartridge body 194, cartridge tray196, and elongated channel 302. When a surgical staple cartridge 304 ispositioned within the elongated channel 302, a slot 193 defined in thecartridge body 194 can be aligned with a longitudinal slot 197 definedin the cartridge tray 196 and a slot 189 defined in the elongatedchannel 302. In use, the I-beam 178 can slide through the alignedlongitudinal slots 193, 197, and 189 wherein, as indicated in FIG. 4,the bottom foot 186 of the I-beam 178 can engage a groove running alongthe bottom surface of elongated channel 302 along the length of slot189, the middle pins 184 can engage the top surfaces of cartridge tray196 along the length of longitudinal slot 197, and the upper pins 180can engage the anvil 306. The I-beam 178 can space, or limit therelative movement between, the anvil 306 and the surgical staplecartridge 304 as the firing bar 172 is advanced distally to fire thestaples from the surgical staple cartridge 304 and/or incise the tissuecaptured between the anvil 306 and the surgical staple cartridge 304.The firing bar 172 and the I-beam 178 can be retracted proximallyallowing the anvil 306 to be opened to release the two stapled andsevered tissue portions.

FIGS. 5A-5B is a block diagram of a control circuit 700 of the surgicalinstrument 10 of FIG. 1 spanning two drawing sheets according to oneaspect of this disclosure. Referring primarily to FIGS. 6A-6B, a handleassembly 702 may include a motor 714 which can be controlled by a motordriver 715 and can be employed by the firing system of the surgicalinstrument 10. In various forms, the motor 714 may be a DC brusheddriving motor having a maximum rotational speed of approximately 25,000RPM. In other arrangements, the motor 714 may include a brushless motor,a cordless motor, a synchronous motor, a stepper motor, or any othersuitable electric motor. The motor driver 715 may comprise an H-Bridgedriver comprising field-effect transistors (FETs) 719, for example. Themotor 714 can be powered by the power assembly 706 releasably mounted tothe handle assembly 200 for supplying control power to the surgicalinstrument 10. The power assembly 706 may comprise a battery which mayinclude a number of battery cells connected in series that can be usedas the power source to power the surgical instrument 10. In certaincircumstances, the battery cells of the power assembly 706 may bereplaceable and/or rechargeable. In at least one example, the batterycells can be Lithium-Ion batteries which can be separably couplable tothe power assembly 706.

The shaft assembly 704 may include a shaft assembly controller 722 whichcan communicate with a safety controller and power management controller716 through an interface while the shaft assembly 704 and the powerassembly 706 are coupled to the handle assembly 702. For example, theinterface may comprise a first interface portion 725 which may includeone or more electric connectors for coupling engagement withcorresponding shaft assembly electric connectors and a second interfaceportion 727 which may include one or more electric connectors forcoupling engagement with corresponding power assembly electricconnectors to permit electrical communication between the shaft assemblycontroller 722 and the power management controller 716 while the shaftassembly 704 and the power assembly 706 are coupled to the handleassembly 702. One or more communication signals can be transmittedthrough the interface to communicate one or more of the powerrequirements of the attached interchangeable shaft assembly 704 to thepower management controller 716. In response, the power managementcontroller may modulate the power output of the battery of the powerassembly 706, as described below in greater detail, in accordance withthe power requirements of the attached shaft assembly 704. Theconnectors may comprise switches which can be activated after mechanicalcoupling engagement of the handle assembly 702 to the shaft assembly 704and/or to the power assembly 706 to allow electrical communicationbetween the shaft assembly controller 722 and the power managementcontroller 716.

The interface can facilitate transmission of the one or morecommunication signals between the power management controller 716 andthe shaft assembly controller 722 by routing such communication signalsthrough a main controller 717 residing in the handle assembly 702, forexample. In other circumstances, the interface can facilitate a directline of communication between the power management controller 716 andthe shaft assembly controller 722 through the handle assembly 702 whilethe shaft assembly 704 and the power assembly 706 are coupled to thehandle assembly 702.

The main controller 717 may be any single core or multicore processorsuch as those known under the trade name ARM Cortex by TexasInstruments. In one aspect, the main controller 717 may be anLM4F230H5QR ARM Cortex-M4F Processor Core, available from TexasInstruments, for example, comprising on-chip memory of 256 KBsingle-cycle flash memory, or other non-volatile memory, up to 40 MHz, aprefetch buffer to improve performance above 40 MHz, a 32 KBsingle-cycle serial random access memory (SRAM), internal read-onlymemory (ROM) loaded with StellarisWare® software, 2 KB electricallyerasable programmable read-only memory (EEPROM), one or more pulse widthmodulation (PWM) modules, one or more quadrature encoder inputs (QEI)analog, one or more 12-bit Analog-to-Digital Converters (ADC) with 12analog input channels, details of which are available for the productdatasheet.

The safety controller may be a safety controller platform comprising twocontroller-based families such as TMS570 and RM4x known under the tradename Hercules ARM Cortex R4, also by Texas Instruments. The safetycontroller may be configured specifically for IEC 61508 and ISO 26262safety critical applications, among others, to provide advancedintegrated safety features while delivering scalable performance,connectivity, and memory options.

The power assembly 706 may include a power management circuit which maycomprise the power management controller 716, a power modulator 738, anda current sense circuit 736. The power management circuit can beconfigured to modulate power output of the battery based on the powerrequirements of the shaft assembly 704 while the shaft assembly 704 andthe power assembly 706 are coupled to the handle assembly 702. The powermanagement controller 716 can be programmed to control the powermodulator 738 of the power output of the power assembly 706 and thecurrent sense circuit 736 can be employed to monitor power output of thepower assembly 706 to provide feedback to the power managementcontroller 716 about the power output of the battery so that the powermanagement controller 716 may adjust the power output of the powerassembly 706 to maintain a desired output. The power managementcontroller 716 and/or the shaft assembly controller 722 each maycomprise one or more processors and/or memory units which may store anumber of software modules.

The surgical instrument 10 (FIGS. 1-4) may comprise an output device 742which may include devices for providing a sensory feedback to a user.Such devices may comprise, for example, visual feedback devices (e.g.,an LCD display screen, LED indicators), audio feedback devices (e.g., aspeaker, a buzzer) or tactile feedback devices (e.g., haptic actuators).In certain circumstances, the output device 742 may comprise a display743 which may be included in the handle assembly 702. The shaft assemblycontroller 722 and/or the power management controller 716 can providefeedback to a user of the surgical instrument 10 through the outputdevice 742. The interface can be configured to connect the shaftassembly controller 722 and/or the power management controller 716 tothe output device 742. The output device 742 can instead be integratedwith the power assembly 706. In such circumstances, communicationbetween the output device 742 and the shaft assembly controller 722 maybe accomplished through the interface while the shaft assembly 704 iscoupled to the handle assembly 702.

The control circuit 700 comprises circuit segments configured to controloperations of the powered surgical instrument 10. A safety controllersegment (Segment 1) comprises a safety controller and the maincontroller 717 segment (Segment 2). The safety controller and/or themain controller 717 are configured to interact with one or moreadditional circuit segments such as an acceleration segment, a displaysegment, a shaft segment, an encoder segment, a motor segment, and apower segment. Each of the circuit segments may be coupled to the safetycontroller and/or the main controller 717. The main controller 717 isalso coupled to a flash memory. The main controller 717 also comprises aserial communication interface. The main controller 717 comprises aplurality of inputs coupled to, for example, one or more circuitsegments, a battery, and/or a plurality of switches. The segmentedcircuit may be implemented by any suitable circuit, such as, forexample, a printed circuit board assembly (PCBA) within the poweredsurgical instrument 10. It should be understood that the term processoras used herein includes any microprocessor, processors, controller,controllers, or other basic computing device that incorporates thefunctions of a computer's central processing unit (CPU) on an integratedcircuit or at most a few integrated circuits. The main controller 717 isa multipurpose, programmable device that accepts digital data as input,processes it according to instructions stored in its memory, andprovides results as output. It is an example of sequential digitallogic, as it has internal memory. The control circuit 700 can beconfigured to implement one or more of the processes described herein.

The acceleration segment (Segment 3) comprises an accelerometer. Theaccelerometer is configured to detect movement or acceleration of thepowered surgical instrument 10. Input from the accelerometer may be usedto transition to and from a sleep mode, identify an orientation of thepowered surgical instrument, and/or identify when the surgicalinstrument has been dropped. In some examples, the acceleration segmentis coupled to the safety controller and/or the main controller 717.

The display segment (Segment 4) comprises a display connector coupled tothe main controller 717. The display connector couples the maincontroller 717 to a display through one or more integrated circuitdrivers of the display. The integrated circuit drivers of the displaymay be integrated with the display and/or may be located separately fromthe display. The display may comprise any suitable display, such as, forexample, an organic light-emitting diode (OLED) display, aliquid-crystal display (LCD), and/or any other suitable display. In someexamples, the display segment is coupled to the safety controller.

The shaft segment (Segment 5) comprises controls for an interchangeableshaft assembly 200 (FIGS. 1 and 3) coupled to the surgical instrument 10(FIGS. 1-4) and/or one or more controls for an end effector 300 coupledto the interchangeable shaft assembly 200. The shaft segment comprises ashaft connector configured to couple the main controller 717 to a shaftPCBA. The shaft PCBA comprises a low-power microcontroller with aferroelectric random access memory (FRAM), an articulation switch, ashaft release Hall effect switch, and a shaft PCBA EEPROM. The shaftPCBA EEPROM comprises one or more parameters, routines, and/or programsspecific to the interchangeable shaft assembly 200 and/or the shaftPCBA. The shaft PCBA may be coupled to the interchangeable shaftassembly 200 and/or integral with the surgical instrument 10. In someexamples, the shaft segment comprises a second shaft EEPROM. The secondshaft EEPROM comprises a plurality of algorithms, routines, parameters,and/or other data corresponding to one or more shaft assemblies 200and/or end effectors 300 that may be interfaced with the poweredsurgical instrument 10.

The position encoder segment (Segment 6) comprises one or more magneticangle rotary position encoders. The one or more magnetic angle rotaryposition encoders are configured to identify the rotational position ofthe motor 714, an interchangeable shaft assembly 200 (FIGS. 1 and 3),and/or an end effector 300 of the surgical instrument 10 (FIGS. 1-4). Insome examples, the magnetic angle rotary position encoders may becoupled to the safety controller and/or the main controller 717.

The motor circuit segment (Segment 7) comprises a motor 714 configuredto control movements of the powered surgical instrument 10 (FIGS. 1-4).The motor 714 is coupled to the main microcontroller processor 717 by anH-bridge driver comprising one or more H-bridge field-effect transistors(FETs) and a motor controller. The H-bridge driver is also coupled tothe safety controller. A motor current sensor is coupled in series withthe motor to measure the current draw of the motor. The motor currentsensor is in signal communication with the main controller 717 and/orthe safety controller. In some examples, the motor 714 is coupled to amotor electromagnetic interference (EMI) filter.

The motor controller controls a first motor flag and a second motor flagto indicate the status and position of the motor 714 to the maincontroller 717. The main controller 717 provides a pulse-widthmodulation (PWM) high signal, a PWM low signal, a direction signal, asynchronize signal, and a motor reset signal to the motor controllerthrough a buffer. The power segment is configured to provide a segmentvoltage to each of the circuit segments.

The power segment (Segment 8) comprises a battery coupled to the safetycontroller, the main controller 717, and additional circuit segments.The battery is coupled to the segmented circuit by a battery connectorand a current sensor. The current sensor is configured to measure thetotal current draw of the segmented circuit. In some examples, one ormore voltage converters are configured to provide predetermined voltagevalues to one or more circuit segments. For example, in some examples,the segmented circuit may comprise 3.3V voltage converters and/or 5Vvoltage converters. A boost converter is configured to provide a boostvoltage up to a predetermined amount, such as, for example, up to 13V.The boost converter is configured to provide additional voltage and/orcurrent during power intensive operations and prevent brownout orlow-power conditions.

A plurality of switches are coupled to the safety controller and/or themain controller 717. The switches may be configured to controloperations of the surgical instrument 10 (FIGS. 1-4), of the segmentedcircuit, and/or indicate a status of the surgical instrument 10. Abail-out door switch and Hall effect switch for bailout are configuredto indicate the status of a bail-out door. A plurality of articulationswitches, such as, for example, a left side articulation left switch, aleft side articulation right switch, a left side articulation centerswitch, a right side articulation left switch, a right side articulationright switch, and a right side articulation center switch are configuredto control articulation of an interchangeable shaft assembly 200 (FIGS.1 and 3) and/or the end effector 300 (FIGS. 1 and 4). A left sidereverse switch and a right side reverse switch are coupled to the maincontroller 717. The left side switches comprising the left sidearticulation left switch, the left side articulation right switch, theleft side articulation center switch, and the left side reverse switchare coupled to the main controller 717 by a left flex connector. Theright side switches comprising the right side articulation left switch,the right side articulation right switch, the right side articulationcenter switch, and the right side reverse switch are coupled to the maincontroller 717 by a right flex connector. A firing switch, a clamprelease switch, and a shaft engaged switch are coupled to the maincontroller 717.

Any suitable mechanical, electromechanical, or solid state switches maybe employed to implement the plurality of switches, in any combination.For example, the switches may be limit switches operated by the motionof components associated with the surgical instrument 10 (FIGS. 1-4) orthe presence of an object. Such switches may be employed to controlvarious functions associated with the surgical instrument 10. A limitswitch is an electromechanical device that consists of an actuatormechanically linked to a set of contacts. When an object comes intocontact with the actuator, the device operates the contacts to make orbreak an electrical connection. Limit switches are used in a variety ofapplications and environments because of their ruggedness, ease ofinstallation, and reliability of operation. They can determine thepresence or absence, passing, positioning, and end of travel of anobject. In other implementations, the switches may be solid stateswitches that operate under the influence of a magnetic field such asHall-effect devices, magneto-resistive (MR) devices, giantmagneto-resistive (GMR) devices, magnetometers, among others. In otherimplementations, the switches may be solid state switches that operateunder the influence of light, such as optical sensors, infrared sensors,ultraviolet sensors, among others. Still, the switches may be solidstate devices such as transistors (e.g., FET, Junction-FET, metal-oxidesemiconductor-FET (MOSFET), bipolar, and the like). Other switches mayinclude wireless switches, ultrasonic switches, accelerometers, inertialsensors, among others.

FIG. 6 is another block diagram of the control circuit 700 of thesurgical instrument of FIG. 1 illustrating interfaces between the handleassembly 702 and the power assembly 706 and between the handle assembly702 and the interchangeable shaft assembly 704 according to one aspectof this disclosure. The handle assembly 702 may comprise a maincontroller 717, a shaft assembly connector 726 and a power assemblyconnector 730. The power assembly 706 may include a power assemblyconnector 732, a power management circuit 734 that may comprise thepower management controller 716, a power modulator 738, and a currentsense circuit 736. The shaft assembly connectors 730, 732 form aninterface 727. The power management circuit 734 can be configured tomodulate power output of the battery 707 based on the power requirementsof the interchangeable shaft assembly 704 while the interchangeableshaft assembly 704 and the power assembly 706 are coupled to the handleassembly 702. The power management controller 716 can be programmed tocontrol the power modulator 738 of the power output of the powerassembly 706 and the current sense circuit 736 can be employed tomonitor power output of the power assembly 706 to provide feedback tothe power management controller 716 about the power output of thebattery 707 so that the power management controller 716 may adjust thepower output of the power assembly 706 to maintain a desired output. Theshaft assembly 704 comprises a shaft processor 719 coupled to anon-volatile memory 721 and shaft assembly connector 728 to electricallycouple the shaft assembly 704 to the handle assembly 702. The shaftassembly connectors 726, 728 form interface 725. The main controller717, the shaft processor 719, and/or the power management controller 716can be configured to implement one or more of the processes describedherein.

The surgical instrument 10 (FIGS. 1-4) may comprise an output device 742to a sensory feedback to a user. Such devices may comprise visualfeedback devices (e.g., an LCD display screen, LED indicators), audiofeedback devices (e.g., a speaker, a buzzer), or tactile feedbackdevices (e.g., haptic actuators). In certain circumstances, the outputdevice 742 may comprise a display 743 that may be included in the handleassembly 702. The shaft assembly controller 722 and/or the powermanagement controller 716 can provide feedback to a user of the surgicalinstrument 10 through the output device 742. The interface 727 can beconfigured to connect the shaft assembly controller 722 and/or the powermanagement controller 716 to the output device 742. The output device742 can be integrated with the power assembly 706. Communication betweenthe output device 742 and the shaft assembly controller 722 may beaccomplished through the interface 725 while the interchangeable shaftassembly 704 is coupled to the handle assembly 702. Having described acontrol circuit 700 (FIGS. 5A-5B and 6) for controlling the operation ofthe surgical instrument 10 (FIGS. 1-4), the disclosure now turns tovarious configurations of the surgical instrument 10 (FIGS. 1-4) andcontrol circuit 700.

FIG. 7 illustrates a control circuit 800 configured to control aspectsof the surgical instrument 10 (FIGS. 1-4) according to one aspect ofthis disclosure. The control circuit 800 can be configured to implementvarious processes described herein. The control circuit 800 may comprisea controller comprising one or more processors 802 (e.g.,microprocessor, microcontroller) coupled to at least one memory circuit804. The memory circuit 804 stores machine executable instructions thatwhen executed by the processor 802, cause the processor 802 to executemachine instructions to implement various processes described herein.The processor 802 may be any one of a number of single or multi-coreprocessors known in the art. The memory circuit 804 may comprisevolatile and non-volatile storage media. The processor 802 may includean instruction processing unit 806 and an arithmetic unit 808. Theinstruction processing unit may be configured to receive instructionsfrom the memory circuit 804.

FIG. 8 illustrates a combinational logic circuit 810 configured tocontrol aspects of the surgical instrument 10 (FIGS. 1-4) according toone aspect of this disclosure. The combinational logic circuit 810 canbe configured to implement various processes described herein. Thecircuit 810 may comprise a finite state machine comprising acombinational logic circuit 812 configured to receive data associatedwith the surgical instrument 10 at an input 814, process the data by thecombinational logic 812, and provide an output 816.

FIG. 9 illustrates a sequential logic circuit 820 configured to controlaspects of the surgical instrument 10 (FIGS. 1-4) according to oneaspect of this disclosure. The sequential logic circuit 820 or thecombinational logic circuit 822 can be configured to implement variousprocesses described herein. The circuit 820 may comprise a finite statemachine. The sequential logic circuit 820 may comprise a combinationallogic circuit 822, at least one memory circuit 824, and a clock 829, forexample. The at least one memory circuit 820 can store a current stateof the finite state machine. In certain instances, the sequential logiccircuit 820 may be synchronous or asynchronous. The combinational logiccircuit 822 is configured to receive data associated with the surgicalinstrument 10 an input 826, process the data by the combinational logiccircuit 822, and provide an output 828. In other aspects, the circuitmay comprise a combination of the processor 802 and the finite statemachine to implement various processes herein. In other aspects, thefinite state machine may comprise a combination of the combinationallogic circuit 810 and the sequential logic circuit 820.

Aspects may be implemented as an article of manufacture. The article ofmanufacture may include a computer readable storage medium arranged tostore logic, instructions, and/or data for performing various operationsof one or more aspects. For example, the article of manufacture maycomprise a magnetic disk, optical disk, flash memory, or firmwarecontaining computer program instructions suitable for execution by ageneral purpose processor or application specific processor.

FIG. 10 is a diagram of an absolute positioning system 1100 of thesurgical instrument 10 (FIGS. 1-4) where the absolute positioning system1100 comprises a controlled motor drive circuit arrangement comprising asensor arrangement 1102 according to one aspect of this disclosure. Thesensor arrangement 1102 for an absolute positioning system 1100 providesa unique position signal corresponding to the location of a displacementmember 1111. Turning briefly to FIGS. 2-4, in one aspect thedisplacement member 1111 represents the longitudinally movable drivemember 120 (FIG. 2) comprising a rack of drive teeth 122 for meshingengagement with a corresponding drive gear 86 of the gear reducerassembly 84. In other aspects, the displacement member 1111 representsthe firing member 220 (FIG. 3), which could be adapted and configured toinclude a rack of drive teeth. In yet another aspect, the displacementmember 1111 represents the firing bar 172 (FIG. 4) or the I-beam 178(FIG. 4), each of which can be adapted and configured to include a rackof drive teeth. Accordingly, as used herein, the term displacementmember is used generically to refer to any movable member of thesurgical instrument 10 such as the drive member 120, the firing member220, the firing bar 172, the I-beam 178, or any element that can bedisplaced. In one aspect, the longitudinally movable drive member 120 iscoupled to the firing member 220, the firing bar 172, and the I-beam178. Accordingly, the absolute positioning system 1100 can, in effect,track the linear displacement of the I-beam 178 by tracking the lineardisplacement of the longitudinally movable drive member 120. In variousother aspects, the displacement member 1111 may be coupled to any sensorsuitable for measuring linear displacement. Thus, the longitudinallymovable drive member 120, the firing member 220, the firing bar 172, orthe I-beam 178, or combinations, may be coupled to any suitable lineardisplacement sensor. Linear displacement sensors may include contact ornon-contact displacement sensors. Linear displacement sensors maycomprise linear variable differential transformers (LVDT), differentialvariable reluctance transducers (DVRT), a slide potentiometer, amagnetic sensing system comprising a movable magnet and a series oflinearly arranged Hall effect sensors, a magnetic sensing systemcomprising a fixed magnet and a series of movable linearly arranged Halleffect sensors, an optical sensing system comprising a movable lightsource and a series of linearly arranged photo diodes or photodetectors, or an optical sensing system comprising a fixed light sourceand a series of movable linearly arranged photo diodes or photodetectors, or any combination thereof.

An electric motor 1120 can include a rotatable shaft 1116 that operablyinterfaces with a gear assembly 1114 that is mounted in meshingengagement with a set, or rack, of drive teeth on the displacementmember 1111. A sensor element 1126 may be operably coupled to a gearassembly 1114 such that a single revolution of the sensor element 1126corresponds to some linear longitudinal translation of the displacementmember 1111. An arrangement of gearing and sensors 1118 can be connectedto the linear actuator via a rack and pinion arrangement or a rotaryactuator via a spur gear or other connection. A power source 1129supplies power to the absolute positioning system 1100 and an outputindicator 1128 may display the output of the absolute positioning system1100. In FIG. 2, the displacement member 1111 represents thelongitudinally movable drive member 120 comprising a rack of drive teeth122 formed thereon for meshing engagement with a corresponding drivegear 86 of the gear reducer assembly 84. The displacement member 1111represents the longitudinally movable firing member 220, firing bar 172,I-beam 178, or combinations thereof.

A single revolution of the sensor element 1126 associated with theposition sensor 1112 is equivalent to a longitudinal linear displacementd1 of the of the displacement member 1111, where d1 is the longitudinallinear distance that the displacement member 1111 moves from point “a”to point “b” after a single revolution of the sensor element 1126coupled to the displacement member 1111. The sensor arrangement 1102 maybe connected via a gear reduction that results in the position sensor1112 completing one or more revolutions for the full stroke of thedisplacement member 1111. The position sensor 1112 may complete multiplerevolutions for the full stroke of the displacement member 1111.

A series of switches 1122 a-1122 n, where n is an integer greater thanone, may be employed alone or in combination with gear reduction toprovide a unique position signal for more than one revolution of theposition sensor 1112. The state of the switches 1122 a-1122 n are fedback to a controller 1104 that applies logic to determine a uniqueposition signal corresponding to the longitudinal linear displacementd1+d2+ . . . dn of the displacement member 1111. The output 1124 of theposition sensor 1112 is provided to the controller 1104. The positionsensor 1112 of the sensor arrangement 1102 may comprise a magneticsensor, an analog rotary sensor like a potentiometer, an array of analogHall-effect elements, which output a unique combination of positionsignals or values.

The absolute positioning system 1100 provides an absolute position ofthe displacement member 1111 upon power up of the instrument withoutretracting or advancing the displacement member 1111 to a reset (zero orhome) position as may be required with conventional rotary encoders thatmerely count the number of steps forwards or backwards that the motor1120 has taken to infer the position of a device actuator, drive bar,knife, and the like.

The controller 1104 may be programmed to perform various functions suchas precise control over the speed and position of the knife andarticulation systems. In one aspect, the controller 1104 includes aprocessor 1108 and a memory 1106. The electric motor 1120 may be abrushed DC motor with a gearbox and mechanical links to an articulationor knife system. In one aspect, a motor driver 1110 may be an A3941available from Allegro Microsystems, Inc. Other motor drivers may bereadily substituted for use in the absolute positioning system 1100. Amore detailed description of the absolute positioning system 1100 isdescribed in U.S. patent application Ser. No. 15/130,590, entitledSYSTEMS AND METHODS FOR CONTROLLING A SURGICAL STAPLING AND CUTTINGINSTRUMENT, filed on Apr. 15, 2016, the entire disclosure of which isherein incorporated by reference.

The controller 1104 may be programmed to provide precise control overthe speed and position of the displacement member 1111 and articulationsystems. The controller 1104 may be configured to compute a response inthe software of the controller 1104. The computed response is comparedto a measured response of the actual system to obtain an “observed”response, which is used for actual feedback decisions. The observedresponse is a favorable, tuned, value that balances the smooth,continuous nature of the simulated response with the measured response,which can detect outside influences on the system.

The absolute positioning system 1100 may comprise and/or be programmedto implement a feedback controller, such as a PID, state feedback, andadaptive controller. A power source 1129 converts the signal from thefeedback controller into a physical input to the system, in this casevoltage. Other examples include pulse width modulation (PWM) of thevoltage, current, and force. Other sensor(s) 1118 may be provided tomeasure physical parameters of the physical system in addition toposition measured by the position sensor 1112. In a digital signalprocessing system, absolute positioning system 1100 is coupled to adigital data acquisition system where the output of the absolutepositioning system 1100 will have finite resolution and samplingfrequency. The absolute positioning system 1100 may comprise a compareand combine circuit to combine a computed response with a measuredresponse using algorithms such as weighted average and theoreticalcontrol loop that drives the computed response towards the measuredresponse. The computed response of the physical system takes intoaccount properties like mass, inertial, viscous friction, inductanceresistance, etc., to predict what the states and outputs of the physicalsystem will be by knowing the input. The controller 1104 may be acontrol circuit 700 (FIGS. 5A-5B).

The motor driver 1110 may be an A3941 available from AllegroMicrosystems, Inc. The A3941 driver 1110 is a full-bridge controller foruse with external N-channel power metal oxide semiconductor field effecttransistors (MOSFETs) specifically designed for inductive loads, such asbrush DC motors. The driver 1110 comprises a unique charge pumpregulator provides full (>10 V) gate drive for battery voltages down to7 V and allows the A3941 to operate with a reduced gate drive, down to5.5 V. A bootstrap capacitor may be employed to provide theabove-battery supply voltage required for N-channel MOSFETs. An internalcharge pump for the high-side drive allows DC (100% duty cycle)operation. The full bridge can be driven in fast or slow decay modesusing diode or synchronous rectification. In the slow decay mode,current recirculation can be through the high-side or the lowside FETs.The power FETs are protected from shoot-through by resistor adjustabledead time. Integrated diagnostics provide indication of undervoltage,overtemperature, and power bridge faults, and can be configured toprotect the power MOSFETs under most short circuit conditions. Othermotor drivers may be readily substituted for use in the absolutepositioning system 1100.

Having described a general architecture for implementing aspects of anabsolute positioning system 1100 for a sensor arrangement 1102, thedisclosure now turns to FIGS. 11 and 12 fora description of one aspectof a sensor arrangement 1102 for the absolute positioning system 1100.FIG. 11 is an exploded perspective view of the sensor arrangement 1102for the absolute positioning system 1100 showing a circuit 1205 and therelative alignment of the elements of the sensor arrangement 1102,according to one aspect. The sensor arrangement 1102 for an absolutepositioning system 1100 comprises a position sensor 1200, a magnet 1202sensor element, a magnet holder 1204 that turns once every full strokeof the displacement member 1111, and a gear assembly 1206 to provide agear reduction. With reference briefly to FIG. 2, the displacementmember 1111 may represent the longitudinally movable drive member 120comprising a rack of drive teeth 122 for meshing engagement with acorresponding drive gear 86 of the gear reducer assembly 84. Returningto FIG. 11, a structural element such as bracket 1216 is provided tosupport the gear assembly 1206, the magnet holder 1204, and the magnet1202. The position sensor 1200 comprises magnetic sensing elements suchas Hall elements and is placed in proximity to the magnet 1202. As themagnet 1202 rotates, the magnetic sensing elements of the positionsensor 1200 determine the absolute angular position of the magnet 1202over one revolution.

The sensor arrangement 1102 may comprises any number of magnetic sensingelements, such as, for example, magnetic sensors classified according towhether they measure the total magnetic field or the vector componentsof the magnetic field. The techniques used to produce both types ofmagnetic sensors encompass many aspects of physics and electronics. Thetechnologies used for magnetic field sensing include search coil,fluxgate, optically pumped, nuclear precession, SQUID, Hall-effect,anisotropic magnetoresistance, giant magnetoresistance, magnetic tunneljunctions, giant magnetoimpedance, magnetostrictive/piezoelectriccomposites, magnetodiode, magnetotransistor, fiber optic, magnetooptic,and microelectromechanical systems-based magnetic sensors, among others.

A gear assembly comprises a first gear 1208 and a second gear 1210 inmeshing engagement to provide a 3:1 gear ratio connection. A third gear1212 rotates about a shaft 1214. The third gear 1212 is in meshingengagement with the displacement member 1111 (or 120 as shown in FIG. 2)and rotates in a first direction as the displacement member 1111advances in a distal direction D and rotates in a second direction asthe displacement member 1111 retracts in a proximal direction P. Thesecond gear 1210 also rotates about the shaft 1214 and, therefore,rotation of the second gear 1210 about the shaft 1214 corresponds to thelongitudinal translation of the displacement member 1111. Thus, one fullstroke of the displacement member 1111 in either the distal or proximaldirections D, P corresponds to three rotations of the second gear 1210and a single rotation of the first gear 1208. Since the magnet holder1204 is coupled to the first gear 1208, the magnet holder 1204 makes onefull rotation with each full stroke of the displacement member 1111.

The position sensor 1200 is supported by a position sensor holder 1218defining an aperture 1220 suitable to contain the position sensor 1200in precise alignment with a magnet 1202 rotating below within the magnetholder 1204. The fixture is coupled to the bracket 1216 and to thecircuit 1205 and remains stationary while the magnet 1202 rotates withthe magnet holder 1204. A hub 1222 is provided to mate with the firstgear 1208 and the magnet holder 1204. The second gear 1210 and thirdgear 1212 coupled to shaft 1214 also are shown.

FIG. 12 is a diagram of a position sensor 1200 for an absolutepositioning system 1100 comprising a magnetic rotary absolutepositioning system according to one aspect of this disclosure. Theposition sensor 1200 may be implemented as an AS5055EQFT single-chipmagnetic rotary position sensor available from Austria Microsystems, AG.The position sensor 1200 is interfaced with the controller 1104 toprovide an absolute positioning system 1100. The position sensor 1200 isa low-voltage and low-power component and includes four Hall-effectelements 1228A, 1228B, 1228C, 1228D in an area 1230 of the positionsensor 1200 that is located above the magnet 1202 (FIGS. 15 and 16). Ahigh-resolution ADC 1232 and a smart power management controller 1238are also provided on the chip. A CORDIC processor 1236 (for CoordinateRotation Digital Computer), also known as the digit-by-digit method andVolder's algorithm, is provided to implement a simple and efficientalgorithm to calculate hyperbolic and trigonometric functions thatrequire only addition, subtraction, bitshift, and table lookupoperations. The angle position, alarm bits, and magnetic fieldinformation are transmitted over a standard serial communicationinterface such as an SPI interface 1234 to the controller 1104. Theposition sensor 1200 provides 12 or 14 bits of resolution. The positionsensor 1200 may be an AS5055 chip provided in a small QFN 16-pin4×4×0.85 mm package.

The Hall-effect elements 1228A, 1228B, 1228C, 1228D are located directlyabove the rotating magnet 1202 (FIG. 11). The Hall-effect is awell-known effect and for expediency will not be described in detailherein, however, generally, the Hall-effect produces a voltagedifference (the Hall voltage) across an electrical conductor transverseto an electric current in the conductor and a magnetic fieldperpendicular to the current. A Hall coefficient is defined as the ratioof the induced electric field to the product of the current density andthe applied magnetic field. It is a characteristic of the material fromwhich the conductor is made, since its value depends on the type,number, and properties of the charge carriers that constitute thecurrent. In the AS5055 position sensor 1200, the Hall-effect elements1228A, 1228B, 1228C, 1228D are capable producing a voltage signal thatis indicative of the absolute position of the magnet 1202 in terms ofthe angle over a single revolution of the magnet 1202. This value of theangle, which is unique position signal, is calculated by the CORDICprocessor 1236 is stored onboard the AS5055 position sensor 1200 in aregister or memory. The value of the angle that is indicative of theposition of the magnet 1202 over one revolution is provided to thecontroller 1104 in a variety of techniques, e.g., upon power up or uponrequest by the controller 1104.

The AS5055 position sensor 1200 requires only a few external componentsto operate when connected to the controller 1104. Six wires are neededfor a simple application using a single power supply: two wires forpower and four wires 1240 for the SPI interface 1234 with the controller1104. A seventh connection can be added in order to send an interrupt tothe controller 1104 to inform that a new valid angle can be read. Uponpower-up, the AS5055 position sensor 1200 performs a full power-upsequence including one angle measurement. The completion of this cycleis indicated as an INT output 1242, and the angle value is stored in aninternal register. Once this output is set, the AS5055 position sensor1200 suspends to sleep mode. The controller 1104 can respond to the INTrequest at the INT output 1242 by reading the angle value from theAS5055 position sensor 1200 over the SPI interface 1234. Once the anglevalue is read by the controller 1104, the INT output 1242 is clearedagain. Sending a “read angle” command by the SPI interface 1234 by thecontroller 1104 to the position sensor 1200 also automatically powers upthe chip and starts another angle measurement. As soon as the controller1104 has completed reading of the angle value, the INT output 1242 iscleared and a new result is stored in the angle register. The completionof the angle measurement is again indicated by setting the INT output1242 and a corresponding flag in the status register.

Due to the measurement principle of the AS5055 position sensor 1200,only a single angle measurement is performed in very short time (˜600μs) after each power-up sequence. As soon as the measurement of oneangle is completed, the AS5055 position sensor 1200 suspends topower-down state. An on-chip filtering of the angle value by digitalaveraging is not implemented, as this would require more than one anglemeasurement and, consequently, a longer power-up time that is notdesired in low-power applications. The angle jitter can be reduced byaveraging of several angle samples in the controller 1104. For example,an averaging of four samples reduces the jitter by 6 dB (50%).

FIG. 13 is a section view of an end effector 2502 of the surgicalinstrument 10 (FIGS. 1-4) showing an I-beam 2514 firing stroke relativeto tissue 2526 grasped within the end effector 2502 according to oneaspect of this disclosure. The end effector 2502 is configured tooperate with the surgical instrument 10 shown in FIGS. 1-4. The endeffector 2502 comprises an anvil 2516 and an elongated channel 2503 witha staple cartridge 2518 positioned in the elongated channel 2503. Afiring bar 2520 is translatable distally and proximally along alongitudinal axis 2515 of the end effector 2502. When the end effector2502 is not articulated, the end effector 2502 is in line with the shaftof the instrument. An I-beam 2514 comprising a cutting edge 2509 isillustrated at a distal portion of the firing bar 2520. A wedge sled2513 is positioned in the staple cartridge 2518. As the I-beam 2514translates distally, the cutting edge 2509 contacts and may cut tissue2526 positioned between the anvil 2516 and the staple cartridge 2518.Also, the I-beam 2514 contacts the wedge sled 2513 and pushes itdistally, causing the wedge sled 2513 to contact staple drivers 2511.The staple drivers 2511 may be driven up into staples 2505, causing thestaples 2505 to advance through tissue and into pockets 2507 defined inthe anvil 2516, which shape the staples 2505.

An example I-beam 2514 firing stroke is illustrated by a chart 2529aligned with the end effector 2502. Example tissue 2526 is also shownaligned with the end effector 2502. The firing member stroke maycomprise a stroke begin position 2527 and a stroke end position 2528.During an I-beam 2514 firing stroke, the I-beam 2514 may be advanceddistally from the stroke begin position 2527 to the stroke end position2528. The I-beam 2514 is shown at one example location of a stroke beginposition 2527. The I-beam 2514 firing member stroke chart 2529illustrates five firing member stroke regions 2517, 2519, 2521, 2523,2525. In a first firing stroke region 2517, the I-beam 2514 may begin toadvance distally. In the first firing stroke region 2517, the I-beam2514 may contact the wedge sled 2513 and begin to move it distally.While in the first region, however, the cutting edge 2509 may notcontact tissue and the wedge sled 2513 may not contact a staple driver2511. After static friction is overcome, the force to drive the I-beam2514 in the first region 2517 may be substantially constant.

In the second firing member stroke region 2519, the cutting edge 2509may begin to contact and cut tissue 2526. Also, the wedge sled 2513 maybegin to contact staple drivers 2511 to drive staples 2505. Force todrive the I-beam 2514 may begin to ramp up. As shown, tissue encounteredinitially may be compressed and/or thinner because of the way that theanvil 2516 pivots relative to the staple cartridge 2518. In the thirdfiring member stroke region 2521, the cutting edge 2509 may continuouslycontact and cut tissue 2526 and the wedge sled 2513 may repeatedlycontact staple drivers 2511. Force to drive the I-beam 2514 may plateauin the third region 2521. By the fourth firing stroke region 2523, forceto drive the I-beam 2514 may begin to decline. For example, tissue inthe portion of the end effector 2502 corresponding to the fourth firingregion 2523 may be less compressed than tissue closer to the pivot pointof the anvil 2516, requiring less force to cut. Also, the cutting edge2509 and wedge sled 2513 may reach the end of the tissue 2526 while inthe fourth region 2523. When the I-beam 2514 reaches the fifth region2525, the tissue 2526 may be completely severed. The wedge sled 2513 maycontact one or more staple drivers 2511 at or near the end of thetissue. Force to advance the I-beam 2514 through the fifth region 2525may be reduced and, in some examples, may be similar to the force todrive the I-beam 2514 in the first region 2517. At the conclusion of thefiring member stroke, the I-beam 2514 may reach the stroke end position2528. The positioning of firing member stroke regions 2517, 2519, 2521,2523, 2525 in FIG. 18 is just one example. In some examples, differentregions may begin at different positions along the end effectorlongitudinal axis 2515, for example, based on the positioning of tissuebetween the anvil 2516 and the staple cartridge 2518.

As discussed above and with reference now to FIGS. 10-13, the electricmotor 1122 positioned within the handle assembly of the surgicalinstrument 10 (FIGS. 1-4) can be utilized to advance and/or retract thefiring system of the shaft assembly, including the I-beam 2514, relativeto the end effector 2502 of the shaft assembly in order to staple and/orincise tissue captured within the end effector 2502. The I-beam 2514 maybe advanced or retracted at a desired speed, or within a range ofdesired speeds. The controller 1104 may be configured to control thespeed of the I-beam 2514. The controller 1104 may be configured topredict the speed of the I-beam 2514 based on various parameters of thepower supplied to the electric motor 1122, such as voltage and/orcurrent, for example, and/or other operating parameters of the electricmotor 1122 or external influences. The controller 1104 may be configuredto predict the current speed of the I-beam 2514 based on the previousvalues of the current and/or voltage supplied to the electric motor1122, and/or previous states of the system like velocity, acceleration,and/or position. The controller 1104 may be configured to sense thespeed of the I-beam 2514 utilizing the absolute positioning sensorsystem described herein. The controller can be configured to compare thepredicted speed of the I-beam 2514 and the sensed speed of the I-beam2514 to determine whether the power to the electric motor 1122 should beincreased in order to increase the speed of the I-beam 2514 and/ordecreased in order to decrease the speed of the I-beam 2514. U.S. Pat.No. 8,210,411, entitled MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, whichis incorporated herein by reference in its entirety. U.S. Pat. No.7,845,537, entitled SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES,which is incorporated herein by reference in its entirety.

Force acting on the I-beam 2514 may be determined using varioustechniques. The I-beam 2514 force may be determined by measuring themotor 2504 current, where the motor 2504 current is based on the loadexperienced by the I-beam 2514 as it advances distally. The I-beam 2514force may be determined by positioning a strain gauge on the drivemember 120 (FIG. 2), the firing member 220 (FIG. 2), I-beam 2514 (I-beam178, FIG. 20), the firing bar 172 (FIG. 2), and/or on a proximal end ofthe cutting edge 2509. The I-beam 2514 force may be determined bymonitoring the actual position of the I-beam 2514 moving at an expectedvelocity based on the current set velocity of the motor 2504 after apredetermined elapsed period T₁ and comparing the actual position of theI-beam 2514 relative to the expected position of the I-beam 2514 basedon the current set velocity of the motor 2504 at the end of the periodT₁. Thus, if the actual position of the I-beam 2514 is less than theexpected position of the I-beam 2514, the force on the I-beam 2514 isgreater than a nominal force. Conversely, if the actual position of theI-beam 2514 is greater than the expected position of the I-beam 2514,the force on the I-beam 2514 is less than the nominal force. Thedifference between the actual and expected positions of the I-beam 2514is proportional to the deviation of the force on the I-beam 2514 fromthe nominal force. Such techniques are described in U.S. PatentApplication Ser. No. 15/628,075, titled SYSTEMS AND METHODS FORCONTROLLING MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTINGINSTRUMENT, now U.S. Patent No. 10,624,633, which is incorporated hereinby reference in its entirety.

FIG. 14 illustrates a block diagram of a surgical instrument 2500programmed to control distal translation of a displacement memberaccording to one aspect of this disclosure. In one aspect, the surgicalinstrument 2500 is programmed to control distal translation of adisplacement member 1111 such as the I-beam 2514. The surgicalinstrument 2500 comprises an end effector 2502 that may comprise ananvil 2516, an I-beam 2514 (including a sharp cutting edge 2509), and aremovable staple cartridge 2518. The end effector 2502, anvil 2516,I-beam 2514, and staple cartridge 2518 may be configured as describedherein, for example, with respect to FIGS. 1-13.

The position, movement, displacement, and/or translation of a linerdisplacement member 1111, such as the I-beam 2514, can be measured bythe absolute positioning system 1100, sensor arrangement 1102, andposition sensor 1200 as shown in FIGS. 10-12 and represented as positionsensor 2534 in FIG. 14. Because the I-beam 2514 is coupled to thelongitudinally movable drive member 120, the position of the I-beam 2514can be determined by measuring the position of the longitudinallymovable drive member 120 employing the position sensor 2534.Accordingly, in the following description, the position, displacement,and/or translation of the I-beam 2514 can be achieved by the positionsensor 2534 as described herein. A control circuit 2510, such as thecontrol circuit 700 described in FIGS. 5A and 5B, may be programmed tocontrol the translation of the displacement member 1111, such as theI-beam 2514, as described in connection with 10-12. The control circuit2510, in some examples, may comprise one or more microcontrollers,microprocessors, or other suitable processors for executing instructionsthat cause the processor or processors to control the displacementmember, e.g., the I-beam 2514, in the manner described. In one aspect, atimer/counter circuit 2531 provides an output signal, such as elapsedtime or a digital count, to the control circuit 2510 to correlate theposition of the I-beam 2514 as determined by the position sensor 2534with the output of the timer/counter circuit 2531 such that the controlcircuit 2510 can determine the position of the I-beam 2514 at a specifictime (t) relative to a starting position. The timer/counter circuit 2531may be configured to measure elapsed time, count external evens, or timeexternal events.

The control circuit 2510 may generate a motor set point signal 2522. Themotor set point signal 2522 may be provided to a motor controller 2508.The motor controller 2508 may comprise one or more circuits configuredto provide a motor drive signal 2524 to the motor 2504 to drive themotor 2504 as described herein. In some examples, the motor 2504 may bea brushed DC electric motor, such as the motor 82, 714, 1120 shown inFIGS. 1, 5B, 10. For example, the velocity of the motor 2504 may beproportional to the motor drive signal 2524. In some examples, the motor2504 may be a brushless direct current (DC) electric motor and the motordrive signal 2524 may comprise a pulse-width-modulated (PWM) signalprovided to one or more stator windings of the motor 2504. Also, in someexamples, the motor controller 2508 may be omitted and the controlcircuit 2510 may generate the motor drive signal 2524 directly.

The motor 2504 may receive power from an energy source 2512. The energysource 2512 may be or include a battery, a super capacitor, or any othersuitable energy source 2512. The motor 2504 may be mechanically coupledto the I-beam 2514 via a transmission 2506. The transmission 2506 mayinclude one or more gears or other linkage components to couple themotor 2504 to the I-beam 2514. A position sensor 2534 may sense aposition of the I-beam 2514. The position sensor 2534 may be or includeany type of sensor that is capable of generating position data thatindicates a position of the I-beam 2514. In some examples, the positionsensor 2534 may include an encoder configured to provide a series ofpulses to the control circuit 2510 as the I-beam 2514 translatesdistally and proximally. The control circuit 2510 may track the pulsesto determine the position of the I-beam 2514. Other suitable positionsensor may be used, including, for example, a proximity sensor. Othertypes of position sensors may provide other signals indicating motion ofthe I-beam 2514. Also, in some examples, the position sensor 2534 may beomitted. Where the motor 2504 is a stepper motor, the control circuit2510 may track the position of the I-beam 2514 by aggregating the numberand direction of steps that the motor 2504 has been instructed toexecute. The position sensor 2534 may be located in the end effector2502 or at any other portion of the instrument.

The control circuit 2510 may be in communication with one or moresensors 2538. The sensors 2538 may be positioned on the end effector2502 and adapted to operate with the surgical instrument 2500 to measurethe various derived parameters such as gap distance versus time, tissuecompression versus time, and anvil strain versus time. The sensors 2538may comprise a magnetic sensor, a magnetic field sensor, a strain gauge,a pressure sensor, a force sensor, an inductive sensor such as an eddycurrent sensor, a resistive sensor, a capacitive sensor, an opticalsensor, and/or any other suitable sensor for measuring one or moreparameters of the end effector 2502. The sensors 2538 may include one ormore sensors.

The one or more sensors 2538 may comprise a strain gauge, such as amicro-strain gauge, configured to measure the magnitude of the strain inthe anvil 2516 during a clamped condition. The strain gauge provides anelectrical signal whose amplitude varies with the magnitude of thestrain. The sensors 2538 may comprise a pressure sensor configured todetect a pressure generated by the presence of compressed tissue betweenthe anvil 2516 and the staple cartridge 2518. The sensors 2538 may beconfigured to detect impedance of a tissue section located between theanvil 2516 and the staple cartridge 2518 that is indicative of thethickness and/or fullness of tissue located therebetween.

The sensors 2538 may be is configured to measure forces exerted on theanvil 2516 by the closure drive system 30. For example, one or moresensors 2538 can be at an interaction point between the closure tube 260(FIG. 3) and the anvil 2516 to detect the closure forces applied by theclosure tube 260 to the anvil 2516. The forces exerted on the anvil 2516can be representative of the tissue compression experienced by thetissue section captured between the anvil 2516 and the staple cartridge2518. The one or more sensors 2538 can be positioned at variousinteraction points along the closure drive system 30 (FIG. 2) to detectthe closure forces applied to the anvil 2516 by the closure drive system30. The one or more sensors 2538 may be sampled in real time during aclamping operation by a processor as described in FIGS. 5A-5B. Thecontrol circuit 2510 receives real-time sample measurements to provideanalyze time based information and assess, in real time, closure forcesapplied to the anvil 2516.

A current sensor 2536 can be employed to measure the current drawn bythe motor 2504. The force required to advance the I-beam 2514corresponds to the current drawn by the motor 2504. The force isconverted to a digital signal and provided to the control circuit 2510.

Using the physical properties of the instruments disclosed herein inconnection with FIGS. 1-14, and with reference to FIG. 14, the controlcircuit 2510 can be configured to simulate the response of the actualsystem of the instrument in the software of the controller. Adisplacement member can be actuated to move an I-beam 2514 in the endeffector 2502 at or near a target velocity. The surgical instrument 2500can include a feedback controller, which can be one of any feedbackcontrollers, including, but not limited to a PID, a State Feedback, LQR,and/or an Adaptive controller, for example. The surgical instrument 2500can include a power source to convert the signal from the feedbackcontroller into a physical input such as case voltage, pulse widthmodulated (PWM) voltage, frequency modulated voltage, current, torque,and/or force, for example.

The actual drive system of the surgical instrument 2500 is configured todrive the displacement member, cutting member, or I-beam 2514, by abrushed DC motor with gearbox and mechanical links to an articulationand/or knife system. Another example is the electric motor 2504 thatoperates the displacement member and the articulation driver, forexample, of an interchangeable shaft assembly. An outside influence isan unmeasured, unpredictable influence of things like tissue,surrounding bodies and friction on the physical system. Such outsideinfluence can be referred to as drag which acts in opposition to theelectric motor 2504. The outside influence, such as drag, may cause theoperation of the physical system to deviate from a desired operation ofthe physical system.

Before explaining aspects of the surgical instrument 2500 in detail, itshould be noted that the example aspects are not limited in applicationor use to the details of construction and arrangement of partsillustrated in the accompanying drawings and description. The exampleaspects may be implemented or incorporated in other aspects, variationsand modifications, and may be practiced or carried out in various ways.Further, unless otherwise indicated, the terms and expressions employedherein have been chosen for the purpose of describing the exampleaspects for the convenience of the reader and are not for the purpose oflimitation thereof. Also, it will be appreciated that one or more of thefollowing-described aspects, expressions of aspects and/or examples, canbe combined with any one or more of the other following-describedaspects, expressions of aspects and/or examples.

Various example aspects are directed to a surgical instrument 2500comprising an end effector 2502 with motor-driven surgical stapling andcutting implements. For example, a motor 2504 may drive a displacementmember distally and proximally along a longitudinal axis of the endeffector 2502. The end effector 2502 may comprise a pivotable anvil 2516and, when configured for use, a staple cartridge 2518 positionedopposite the anvil 2516. A clinician may grasp tissue between the anvil2516 and the staple cartridge 2518, as described herein. When ready touse the instrument 2500, the clinician may provide a firing signal, forexample by depressing a trigger of the instrument 2500. In response tothe firing signal, the motor 2504 may drive the displacement memberdistally along the longitudinal axis of the end effector 2502 from aproximal stroke begin position to a stroke end position distal of thestroke begin position. As the displacement member translates distally,an I-beam 2514 with a cutting element positioned at a distal end, maycut the tissue between the staple cartridge 2518 and the anvil 2516.

In various examples, the surgical instrument 2500 may comprise a controlcircuit 2510 programmed to control the distal translation of thedisplacement member, such as the I-beam 2514, for example, based on oneor more tissue conditions. The control circuit 2510 may be programmed tosense tissue conditions, such as thickness, either directly orindirectly, as described herein. The control circuit 2510 may beprogrammed to select a firing control program based on tissueconditions. A firing control program may describe the distal motion ofthe displacement member. Different firing control programs may beselected to better treat different tissue conditions. For example, whenthicker tissue is present, the control circuit 2510 may be programmed totranslate the displacement member at a lower velocity and/or with lowerpower. When thinner tissue is present, the control circuit 2510 may beprogrammed to translate the displacement member at a higher velocityand/or with higher power.

In some examples, the control circuit 2510 may initially operate themotor 2504 in an open-loop configuration for a first open-loop portionof a stroke of the displacement member. Based on a response of theinstrument 2500 during the open-loop portion of the stroke, the controlcircuit 2510 may select a firing control program. The response of theinstrument may include, a translation distance of the displacementmember during the open-loop portion, a time elapsed during the open-loopportion, energy provided to the motor 2504 during the open-loop portion,a sum of pulse widths of a motor drive signal, etc. After the open-loopportion, the control circuit 2510 may implement the selected firingcontrol program for a second portion of the displacement member stroke.For example, during the closed loop portion of the stroke, the controlcircuit 2510 may modulate the motor 2504 based on translation datadescribing a position of the displacement member in a closed-loop mannerto translate the displacement member at a constant velocity.

FIG. 15 illustrates a diagram 2580 plotting two example displacementmember strokes executed according to one aspect of this disclosure. Thediagram 2580 comprises two axes. A horizontal axis 2584 indicateselapsed time. A vertical axis 2582 indicates the position of the I-beam2514 between a stroke begin position 2586 and a stroke end position2588. On the horizontal axis 2584, the control circuit 2510 may receivethe firing signal and begin providing the initial motor setting at t₀.The open-loop portion of the displacement member stroke is an initialtime period that may elapse between t₀ and t₁.

A first example 2592 shows a response of the surgical instrument 2500when thick tissue is positioned between the anvil 2516 and the staplecartridge 2518. During the open-loop portion of the displacement memberstroke, e.g., the initial time period between t₀ and t₁, the I-beam 2514may traverse from the stroke begin position 2586 to position 2594. Thecontrol circuit 2510 may determine that position 2594 corresponds to afiring control program that advances the I-beam 2514 at a selectedconstant velocity (Vslow), indicated by the slope of the example 2592after t₁ (e.g., in the closed loop portion). The control circuit 2510may drive I-beam 2514 to the velocity Vslow by monitoring the positionof I-beam 2514 and modulating the motor set point 2522 and/or motordrive signal 2524 to maintain Vslow. A second example 2590 shows aresponse of the surgical instrument 2500 when thin tissue is positionedbetween the anvil 2516 and the staple cartridge 2518.

During the initial time period (e.g., the open-loop period) between t₀and t₁, the I-beam 2514 may traverse from the stroke begin position 2586to position 2596. The control circuit may determine that position 2596corresponds to a firing control program that advances the displacementmember at a selected constant velocity (Vfast). Because the tissue inexample 2590 is thinner than the tissue in example 2592, it may provideless resistance to the motion of the I-beam 2514. As a result, theI-beam 2514 may traverse a larger portion of the stroke during theinitial time period. Also, in some examples, thinner tissue (e.g., alarger portion of the displacement member stroke traversed during theinitial time period) may correspond to higher displacement membervelocities after the initial time period.

As described above in connection with FIG. 13-15, a control circuit 2510may be programmed to control the translation of the I-beam 2514. As theI-beam 2514 translates distally, the knife 2509 contacts and may cuttissue between the anvil 2516 and the staple cartridge 2518. Also, theI-beam 2514 contacts the wedge sled 2513 and pushes it distally, causingthe wedge sled 2513 to contact staple drivers 2511. The staple drivers2511 may be driven up into staples 2505, causing the staples 2505 toadvance through tissue and into pockets 2507 defined in the anvil 2516,which shape the staples 2505. The I-beam stroke may comprise a strokebegin position 2527 and a stroke end position 2528. During an I-beamfiring stroke, the I-beam 2514 may be advanced distally from the strokebegin position 2527 to the stroke end position 2528.

The control circuit 2510 may generate a motor set point signal 2522. Themotor set point signal 2522 may be provided to a motor controller 2508.The motor controller 2508 may comprise one or more circuits configuredto provide a motor drive signal 2524 to a motor 2504 to drive the motor2504. The motor 2504 may receive power from an energy source 2512. Themotor 2504 may be mechanically coupled to the I-beam 2514 via atransmission 2506. The transmission 2506 may include one or more gearsor other linkage components to couple the motor 2504 to the I-beam 2514.

Force acting on the I-beam 2514, the force to fire (FTF), may bedetermined using various techniques. In one aspect, the I-beam 2514force may be determined by measuring the motor 2504 current, where themotor 2504 current is based on the load experienced by the I-beam 2514as it advances distally. As illustrated in FIG. 14, a current sensor2536 can be included to measure energy provided to the motor 2504. Thecurrent sensor 2536 may be positioned between the energy source 2512 andthe motor 2504 to measure energy provided by the energy source 2512 tothe motor 2504. The Current sensor 2536 may monitor current drawn by themotor 2504 and may provide data describing the current drawn by themotor 2504 to the control circuit 2510. Any suitable current sensor maybe used such as, for example, a coulomb sensor. Alternatively, in someexamples, the control circuit 2510 may determine the current drawn bythe motor 2504 indirectly.

In another aspect, the I-beam 2514 force may be determined bypositioning a strain gauge on the drive member 120 (FIG. 2), the firingmember 220 (FIG. 2), I-beam 2514 (FIGS. 13 and 14), the firing bar 172(FIG. 2), and/or on a proximal end of the cutting edge 2509. In yetanother aspect, the I-beam 2514 force may be determined by monitoringthe actual position of the I-beam 2514 moving at an expected velocitybased on the current set velocity of the motor 2504 after apredetermined elapsed period T1 and comparing the actual position of theI-beam 2514 relative to the expected position of the I-beam 2514 basedon the current set velocity of the motor 2504 at the end of the periodT1, as described in detail in commonly owned U.S. Patent ApplicationSer. No. 15,628,075, titled SYSTEMS AND METHODS FOR CONTROLLING MOTORVELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENT, now U.S. PatentNo. 10,624,633, which is incorporated herein by reference in itsentirety.

Referring to FIG. 16, a diagram 3500 plots an example 3503 of the forceapplied to fire (FTF) the surgical instrument 2500, the force to fire(FTF) represented by current (I) drawn by the motor 2504. The force tofire (FTF) can be applied to advance the I-beam 2514 during a firingstroke of the surgical instrument 2500. In the diagram 3500, current (I)drawn by the motor 2504 is plotted as a function of the distancetraveled by the I-beam 2514 during a firing stroke. The diagram 3500comprises two axes. A vertical axis 3502 indicates the current (I) inmilliamps, which corresponds to the force to fire (FTF). A horizontalaxis 3504 represents I-beam stroke displacement (d) in millimeters.

In some examples, the control circuit 2510 employs a current sensor 2536to sample the current (I) drawn by the motor 2504 at predeterminedintervals along the distance traveled by the I-beam 2514 during thefiring stroke. In at least one example, the current (I) is sampled in 1mm intervals. In other examples, the current (I) drawn by the motor 2504can be sampled in suitable time intervals during a firing stroke. Thecontrol circuit 2510 may develop a digital current signal based on thesampled current (I) data. In various aspects, the sampled current (I)defines data points, wherein each data point constitutes a current (I)value greater than or equal to a predetermined threshold at apredetermined interval.

Spikes in the current (I) signal can be treated as triggering events forvarious control actions of the surgical instrument 2500. In someexamples, current (I) spikes may indicate malfunctions during a firingstroke that require one or more motor control actions. For example,certain current (I) spikes may be triggering events for motor controlactions that include dynamic braking and/or retracting of the I-beam2514. Furthermore, current (I) spikes occurring in particular portionsor zones of the firing stroke may trigger a lockout of the surgicalinstrument 2500, for example. That said, noise in the current (I) signalmay trigger unnecessary control actions during a firing stroke.Accordingly, discerning between signal noise and event-triggeringcurrent spikes improves the operation of the surgical instrument 2500.

FIG. 17 is a logic flow diagram of a process 3600 depicting a controlprogram or logic configuration representing a firing control programaccording to one aspect of this disclosure. The process 3600 may beexecuted by the surgical instrument 2500 (e.g., the control circuit2510) to implement an I-beam stroke responsive to tissue conditionsand/or staple cartridge type. The control circuit 2510 may receive 3601a firing signal. The firing signal may be received from the trigger 32(FIG. 1) or other suitable actuation device. For example, a clinicianmay place the end effector 2502, clamp tissue between the anvil 2516 andstaple cartridge 2518 and then actuate the trigger 32 to begin a I-beamstroke. The trigger 32 may be configured to provide the firing signal tothe control circuit 2510 upon actuation.

The control circuit 2510, in response to the firing signal, may providea motor setting. For example, the motor setting may be a motor set point2522 provided to the motor controller 2508. The motor controller 2508may translate the motor set point 2522 into a PWM signal, voltagesignal, or other suitable motor drive signal to drive 3602 the motor2504 to translate the displacement member such as , for example, theI-beam 2414. In some examples, (e.g., when the control circuit 2510directly generates the motor drive signal 2524), the motor setting maybe a motor drive signal 2524 provided directly to the motor 2504. Themotor setting may correspond to a particular motor velocity, power, orother suitable variable. In some examples where the motor 2504 is abrushed DC motor, the initial motor setting may be a signal having aconstant voltage. In some examples where the motor is a brushless DCmotor, the initial motor setting may be a signal or set of signalshaving a constant phase, duty cycle, etc.

In the example where the displacement member is the I-beam 2514, thecontrol circuit 2510 may receive 3604 I-beam movement data. I-beammovement data may comprise information (e.g., from the position sensor2534) that describes the position and/or movement of the I-beam 2514.Although receiving I-beam movement data is displayed as a distinct boxin the process 3600, the control circuit 2510 may receive I-beammovement data while the I-beam 2514 is in motion. For example, when theposition sensor 2534 is an encoder, the control circuit 2510 may receivepulse signals from the encoder while the I-beam 2514 is moving with eachpulse signal representing a quantum of motion. Also, in examples wherethe motor 2504 is a stepper motor, the control circuit 2510 may deriveI-beam movement data based on the total number of steps that the controlcircuit 2510 instructs the motor 2504 to execute.

I-beam movement data may indicate a distance that the I-beam 2514 movedduring the initial time period, which may reflect the tissue conditionssuch as the thickness and/or toughness of the tissue present between theanvil 2516 and the staple cartridge 2518 because different types oftissue will offer different levels of resistance. For example, thickeror tougher tissue may provide more mechanical resistance to the knifeand staples. More mechanical resistance may cause the motor 2504 to runmore slowly while the initial motor setting is held substantiallyconstant. Similarly, thinner or weaker tissue may provide lessmechanical resistance to the knife and staples. This may cause the motorto run faster and traverse more distance while the initial motor settingis held substantially constant.

In some examples, the distance traveled by the I-beam 2514 during afiring stroke is divided into a plurality of zones. In the example 3503of the diagram 3500, the distance is divided into six zones. In otherexamples, the distance can be divided into more or less than six zones.In the example 3503 the zones are equal, or at least substantiallyequal, in length. In other examples, the zones may comprise differentlengths.

The control circuit 2510 may also receive 3604 force to fire (FTF) data.Although receiving force to fire (FTF) data is depicted as a distinctfunction of the process 3600, the control circuit 2510 may receive 3604the force to fire (FTF) data while the I-beam 2514 is in motion. Forexample, as described above, the force to fire (FTF) data can be in theform of current (I) drawn by the motor, sampled at predeterminedintervals.

The control circuit 2510 determines 3605 whether the force to fire (FTF)is greater than or equal to a fault threshold. As described above, thecurrent (I) drawn by the motor 2504 may represent the force to fire(FTF) applied to the I-beam 2514 during a firing stroke. Through thesampled current (I) values provided by the current sensor 2536, thecontrol circuit 2510 detects current (I) spikes that are greater than orequal to a predetermined threshold 3510 (FIG. 16), which correspond toforce to fire (FTF) values above the fault threshold. In the example3503, one threshold is assigned to all the zones. In some examples,different zones may be assigned the same or different thresholds. If theforce to fire (FTF) is greater than or equal to the threshold, theprocess 3600 continues along the YES branch and the control circuit 2510determines 3606 whether the position of the I-beam 2514 corresponding tothe current (I) spike is in a predetermined zone or zones. If the forceto fire (FTF) is less than the threshold, the process 3600 continuesalong the NO branch and the control circuit 2510 determines 3609 if theI-beam 2514 is at the end of stroke.

The control circuit 2510 may include a memory storing the value orvalues of the predetermined thresholds. If the control circuit 2510determines that a current (I) spike is greater than or equal to thepredetermined threshold, the control circuit 2510 further determines3606 whether the position of the I-beam 2514 corresponding to thecurrent (I) spike is in a predetermined zone or zones. If the controlcircuit 2510 determines 3606 that a current (I) spike greater than orequal to the predetermined threshold is detected in a predetermined zoneor zones, the control circuit 2510 proceeds along the YES branch andeffects 3607 a motor control action. If, however, no current (I) spikesgreater than or equal to the predetermined threshold 3510 are detectedin the predetermined zone or zones, or a current (I) spike greater thanor equal to the predetermined threshold 3510 are detected outside thepredetermined zone or zones, the control circuit 2510 determines 3609whether the I-beam 2514 has reached the end of stroke. If the I-beam2514 is at the end of the firing stroke, the process 3600 proceeds alongthe YES branch and ends 3611. If the I-beam 2514 is not at the end ofthe firing stroke, the process 3600 proceeds along the NO branch andcontinues to drive 3602 the motor to translate the I-beam 2514. Theprocess 3600 continues until the I-beam 2514 reaches the end of stroke.

The control circuit 2510 may determine whether a present position of theI-beam 2514 is in a predetermined zone or zones based on the movementdata delivered by the position sensor 2534 (FIG. 14). The controlcircuit 2510 may include a memory storing positions of the I-beam 2514and corresponding zones. The control circuit 2510 may compare a currentposition of the I-beam 2514 against the data stored in the memory. Insome examples, current (I) spikes may be treated differently indifferent zones. As illustrated in FIG. 16, a current (I) spike 3506 inan initial portion of the firing stroke such as, for example, zone 1 maybe a triggering event for the control circuit 2510 to effect 3607 amotor control action. Example motor control actions include dynamicbraking and/or retracting of the I-beam 2514. In one example, a suitablemotor control action may involve slowing the motor 2504 to apredetermined velocity until the current (I) drawn by the motor 2504drops below the predetermined threshold.

In some examples, the control circuit 2510 can be configured to performother suitable control actions of the surgical instrument 2500 inresponse to a current (I) spike occurring in a predetermined zone suchas, for example, zone 1. Other suitable control actions of the surgicalinstrument 2500 may include alerting a user as to the status of thesurgical instrument 2500.

Referring to FIG. 18, in various examples, the duration during which theforce to fire (FTF) is maintained at a value greater than or equal tothe predetermined threshold 3510 can aid in discerning between signalnoise and event-triggering spikes improves the operation of the surgicalinstrument 2500. FIG. 18 illustrates an alternative logic flow diagramof another example of a process 3700 depicting a control program thatmay be executed by the surgical instrument 2500 (e.g., the controlcircuit 2510) or a logic configuration to implement an I-beam strokeresponsive to tissue conditions and/or staple cartridge type. Theprocess 3700 is similar in many respects to the process 3600 (FIG. 17).Like the process 3600, in accordance with the process 3700, the controlcircuit 2510 receives 3701 a firing signal, drives 3702 the motor 2504to translate the displacement member such as, for example, the I-beam2514, receives 3704 I-beam movement and force to fire (FTF) data,determines 3705 whether the force to fire (FTF) at a present position ofthe I-beam 2514 is greater than or equal to a predetermined threshold3510, and determines 3706 whether the present position of the I-beam2514 is within a predetermined zone or zones. If the force to fire (FTF)at a present position of the I-beam 2514 is greater than or equal to apredetermined threshold 3510, the process 3700 proceeds along the YESbranch and the control circuit 2510 determines 3708 if the time duration(t) is greater than or equal to (t1). Otherwise, if the force to fire(FTF) is less than the threshold, the process 3700 continues along theNO branch and the control circuit 2510 determines 3709 if the I-beam2514 is at the end of stroke.

The process 3700, however, differs from the process flow 3600 in thatthe process flow 3700 further considers the duration during which aspike of current (I) drawn by the motor 2504, as a representative of theforce to fire (FTF), is maintained at a value greater than or equal tothe predetermined threshold 3510 in determining whether the current (I)spike constitutes a triggering event. Outside of the predetermine zoneor zones the current (I) trigger must be greater than or equal to thepredetermined threshold 3510 by a predefined number of milliseconds inorder to minimize the likelihood that noise within the measurementinadvertently become a triggering event.

If the control circuit 2510 determines 3708 that such time duration (t)is greater than or equal to a predetermined time period (t1), theprocess 3700 proceeds along the YES branch and the control circuit 2510effects 3707 a motor control action, as discussed above in connectionwith 3607. Otherwise, the process 3700 proceeds along the NO branch andthe control circuit determines 3709 if the I-beam 2514 is at the end ofstroke. If the I-beam 2514 is at the end of stroke the process continuesalong the YES branch and the process 3700 ends 3711. Otherwise, theprocess 3700 proceeds along the NO branch and drives 3702 the motor 2504to translate the displacement member such as, for example, the I-beam2514. The process continues until the I-beam 2514 reaches the end of thefiring stroke. In other words, a current (I) spike is only considered anevent triggering spike if it maintained at a value greater than or equalto the predetermined threshold 3510 for a time duration (t) that isgreater than or equal to the predetermined time period (t1). Spikes 3507and 3508 of the example 3503 of the diagram 3500 (FIG. 16) representexample current (I) spikes that exceed the predetermined threshold 3510but are outside a predetermined zone or zones and are only maintainedabove the predetermined threshold 3510 for time periods that are lessthan the predetermined time period (t1). Accordingly, under the processflow 3700 the current (I) spikes 3507 and 3508 are not event triggeringspikes.

In comparison, an alternative current (I) spike 3509 constitutes anevent triggering spike in accordance with the process flow 3700 eventhough the current (I) spike 3509 is outside the predetermined zone orzones because the current (I) spike 3509 is maintained above thepredetermined threshold 3510 for a time duration (t) that is greaterthan the predetermined time period (t1). In some examples, thepredetermined time period (t1) can be selected from a range of about 1millisecond to about 1 second. In some examples, the predetermined timeperiod (t1) can be selected from a range of about 1 millisecond to about500 milliseconds. In some examples, the predetermined time period (t1)can be selected from a range of about 1 millisecond to about 100milliseconds. Other suitable values for the predetermined time period(t1) can be utilized.

In some examples, the control circuit 2510 determines the time duration(t) by maintaining a running counter or timer 2531 (FIG. 16) upondetection of a current (I) value greater than or equal to thepredetermined threshold 3510. The control circuit 2510 maintains therunning counter or timer 2531 as long as subsequent current (I) valuesare also greater than or equal to the predetermined threshold 3510. Thecontrol circuit 2510 may stop or reset the timer 2531 when a subsequentcurrent (I) value is less than the predetermined threshold 3510indicating an end of the time duration (t). In some examples, thecontrol circuit 2510 comprises a processor which may perform thefunction of the timer 2531.

Referring to FIG. 19, in various examples, current (I) spikes indifferent zones along the distance traveled by the I-beam 2514constitute triggering events for different motor control actions. FIG.19 illustrates an alternative logic flow diagram of a process 3800depicting a control program that may be executed by the surgicalinstrument 2500 (e.g., the control circuit 2510) or a logicconfiguration to implement an I-beam stroke responsive to tissueconditions and/or staple cartridge type. The process 3800 is similar inmany respects to the process 3600 (FIG. 17). Like the process 3600, inaccordance with the process 3800 the control circuit 2510 receives 3801a firing signal, drives 3802 the motor 2504 to translate thedisplacement member such as, for example, the I-beam 2514, receives 3804I-beam movement and force to fire (FTF) data, determines 3805 whetherthe force to fire (FTF) at a present position of the I-beam 2514 isgreater than or equal to a predetermined threshold 3510, and determineswhether the present position of the I-beam 2514 is within apredetermined zone. If the force to fire (FTF) at a present position ofthe I-beam 2514 is greater than or equal to a predetermined threshold3510, the process 3800 proceeds along the YES branch and the controlcircuit 2510 determines 3820 if the time duration (t) is greater than orequal to (t1). Otherwise, if the force to fire (FTF) at a presentposition of the I-beam 2514 is less than a predetermined threshold 3510,the process 3800 proceeds along the NO branch and the control circuit2510 determines 3809 if the I-beam 2514 is at the end of stroke. If theI-beam 2514 is the end of stroke, the process 3800 continues along theYES branch and ends 3811. Otherwise, the process 3800 continues alongthe NO branch and the control circuit 2510 receives 3804 the I-beammovement and force to fire (FTF) data. The process 3800 continues untilthe displacement member such as, for example, the I-beam 2514 reachesthe end of stroke.

The process 3800, however, differs from the process 3600 in that theprocess 3800 further considers the time duration (t) during which aspike of current (I) drawn by the motor 2504, as a representative of theforce to fire (FTF), is maintained at a value greater than or equal tothe predetermined threshold 3510 in determining whether the current (I)spike constitutes a triggering event. The process 3800 further selectsbetween different motor control actions.

Accordingly, the control circuit 2510 determines 3820 whether the timeduration (t) during which the current (I) spike is maintained at a valuegreater than or equal to the predetermined threshold 3510 is greaterthan or equal to a first time period (t1). The process 3800 proceedsalong the YES branch and further selects 3807 a first motor controlaction in response to a current (I) spike if the time duration (t)during which the current (I) spike is maintained at a value greater thanor equal to the predetermined threshold 3510 is greater than or equal toa first time period (t1). If, however, the time duration (t) is less isless than the first time period (t1), the control circuit 2510 proceedsalong the NO branch and further determines 3821 if the time duration (t)is greater than or equal than a second time period (t2). The second timeperiod (t2) is less than the first time period (t1). If the timeduration (t) is less than the first duration (t1) and the secondduration (t2), the I-beam 2514 proceeds along the NO branch and thecontrol circuit 2510 determines 3809 if the I-beam 2514 is a the endstroke 3811 and is allowed to continue to the end of the stroke 3811unless it is determined 3822 that the position of the I-beam 2514 wherethe current (I) spike occurred is in either an initial zone such as, forexample, zone 1 or a final zone such as, for example, zone 6. If theI-beam 2514 is not at the end of stroke, the process 3800 continuesalong the NO branch and the control circuit 2510 receives 3804 I-beammovement and force to fire (FTF) data. In some examples, the current (I)spikes in initial and final portions of the firing stroke are lesstolerated than current (I) spikes in an intermediate portion of thefiring stroke.

If the time duration (t) during which the current (I) spike ismaintained at a value greater than or equal to the predeterminedthreshold 3510 is greater than or equal to a second time period (t2),the process continues along the YES branch and the control circuit 2510further determines 3822 whether the current (I) spike occurred in theinitial zone or the final zone. If the position is outside the initialand final predetermined zone the process 3800 proceeds along the NObranch to determine 3809 if the I-beam 2514 is at the end of stroke. Ifthe current (I) spike occurred in the initial zone or the finalpredetermined zone, the process 3800 continues along the YES branch anddetermines 3824 if the position is in the initial predetermined zone andif not true, the process 3800 proceeds along the NO branch and thecontrol circuit 2510 selects 3807 a first motor control action. If,however, the control circuit 2510 determines that the current (I) spikeoccurred in an initial zone, the process 3800 continues along the YESbranch and the control circuit 2510 selects 3825 a second motor controlaction different from the first motor control action. Examples ofsuitable first control actions may include dynamic braking and/orretracting of the I-beam 2514. In one example, a suitable first motorcontrol action may involve slowing the motor 2504 to a predeterminedvelocity until the current (I) drawn by the motor 2504 drops below thepredetermined threshold. An example of a suitable second motor controlaction may include dynamic braking and/or retracting of the I-beam 2514.In one example, the first or initial zone of the firing stroke may be alockout zone, and the second motor control action may include entering alockout state then retracting the I-beam 2514. In the lockout zone, thesecond motor control action may be triggered by any current (I) spikeinstantaneously exceeding the predetermined threshold 3510.

In various examples, the current (I) is sampled in discrete data points,as described above. In such examples, the number of data points abovethe predetermined threshold 3510 can be used with or instead of the timeduration (t), in the process 3700 and/or the process 3800, to determinetriggering events that cause the control circuit 2510 to effectspecified motor control actions. In some examples, the time duration (t)a current spike is maintained above the predetermined threshold can besubstituted with the number of data points above the predeterminedthreshold 3510 in connection with the process 3700 and/or the process3800.

In at least one example pertaining to the process 3700, thedetermination 3708 (FIG. 18) of whether the time duration (t) is greaterthan or equal a predetermined time threshold t₁ is substituted with adetermination of whether the number of data points above thepredetermined threshold 3510 is greater than or equal to a predeterminednumber N1. In another example, pertaining to the process 3800, thedetermination 3820 (FIG. 19) of whether the time duration (t) is greaterthan or equal a predetermined time threshold t₁ is substituted with adetermination of whether the number of data points above thepredetermined threshold 3510 is greater than or equal to a predeterminednumber N1. In addition, the determination 3821 (FIG. 19) of whether thetime duration (t) is further greater than or equal a predetermined timethreshold t₂ is substituted with a determination of whether the numberof data points above the predetermined threshold 3510 is further greaterthan or equal to a predetermined number N2 greater than thepredetermined number N1.

In various examples, the number of data points above the predeterminedthreshold 3510 that are counted can be the number consecutive datapoints above the predetermined threshold 3510. In some examples, everyoccurrence of a data point below the predetermined threshold 3510 resetsthe count. In some examples, the number of data points above thepredetermined threshold 3510 that are counted can be the number of datapoints occurring in a predetermined time period. At the end of thepredetermined time period, the count is reset.

The functions or processes 3600, 3700, 3800 described herein may beexecuted by any of the processing circuits described herein, such as thecontrol circuit 700 described in connection with FIGS. 5-6, the circuits800, 810, 820 described in FIGS. 7-9, the microcontroller 1104 describedin connection with FIGS. 10 and 12, and/or the control circuit 2510described in FIG. 14.

Aspects of the motorized surgical instrument may be practiced withoutthe specific details disclosed herein. Some aspects have been shown asblock diagrams rather than detail. Parts of this disclosure may bepresented in terms of instructions that operate on data stored in acomputer memory. An algorithm refers to a self-consistent sequence ofsteps leading to a desired result, where a “step” refers to amanipulation of physical quantities which may take the form ofelectrical or magnetic signals capable of being stored, transferred,combined, compared, and otherwise manipulated. These signals may bereferred to as bits, values, elements, symbols, characters, terms,numbers. These and similar terms may be associated with the appropriatephysical quantities and are merely convenient labels applied to thesequantities.

Generally, aspects described herein which can be implemented,individually and/or collectively, by a wide range of hardware, software,firmware, or any combination thereof can be viewed as being composed ofvarious types of “electrical circuitry.” Consequently, “electricalcircuitry” includes electrical circuitry having at least one discreteelectrical circuit, electrical circuitry having at least one integratedcircuit, electrical circuitry having at least one application specificintegrated circuit, electrical circuitry forming a general purposecomputing device configured by a computer program (e.g., a generalpurpose computer or processor configured by a computer program which atleast partially carries out processes and/or devices described herein,electrical circuitry forming a memory device (e.g., forms of randomaccess memory), and/or electrical circuitry forming a communicationsdevice (e.g., a modem, communications switch, or optical-electricalequipment). These aspects may be implemented in analog or digital form,or combinations thereof.

The foregoing description has set forth aspects of devices and/orprocesses via the use of block diagrams, flowcharts, and/or examples,which may contain one or more functions and/or operation. Each functionand/or operation within such block diagrams, flowcharts, or examples canbe implemented, individually and/or collectively, by a wide range ofhardware, software, firmware, or virtually any combination thereof. Inone aspect, several portions of the subject matter described herein maybe implemented via Application Specific Integrated Circuits (ASICs),Field Programmable Gate Arrays (FPGAs), digital signal processors(DSPs), Programmable Logic Devices (PLDs), circuits, registers and/orsoftware components, e.g., programs, subroutines, logic and/orcombinations of hardware and software components. logic gates, or otherintegrated formats. Some aspects disclosed herein, in whole or in part,can be equivalently implemented in integrated circuits, as one or morecomputer programs running on one or more computers (e.g., as one or moreprograms running on one or more computer systems), as one or moreprograms running on one or more processors (e.g., as one or moreprograms running on one or more microprocessors), as firmware, or asvirtually any combination thereof, and that designing the circuitryand/or writing the code for the software and or firmware would be wellwithin the skill of one of skill in the art in light of this disclosure.

The mechanisms of the disclosed subject matter are capable of beingdistributed as a program product in a variety of forms, and that anillustrative aspect of the subject matter described herein appliesregardless of the particular type of signal bearing medium used toactually carry out the distribution. Examples of a signal bearing mediuminclude the following: a recordable type medium such as a floppy disk, ahard disk drive, a Compact Disc (CD), a Digital Video Disk (DVD), adigital tape, a computer memory, etc.; and a transmission type mediumsuch as a digital and/or an analog communication medium (e.g., a fiberoptic cable, a waveguide, a wired communications link, a wirelesscommunication link (e.g., transmitter, receiver, transmission logic,reception logic, etc.).

The foregoing description of these aspects has been presented forpurposes of illustration and description. It is not intended to beexhaustive or limiting to the precise form disclosed. Modifications orvariations are possible in light of the above teachings. These aspectswere chosen and described in order to illustrate principles andpractical application to thereby enable one of ordinary skill in the artto utilize the aspects and with modifications as are suited to theparticular use contemplated. It is intended that the claims submittedherewith define the overall scope.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

A surgical instrument, comprising: a displacement member; a motorcoupled to displacement member, the motor operable to translate thedisplacement member; a control circuit coupled to the motor; a parametersensor coupled to the control circuit; and a position sensor coupled tothe control circuit, wherein the control circuit is configured to:receive a parameter output of the parameter sensor indicative of a forceapplied to translate the displacement member; determine a durationduring which the parameter output is maintained at or above apredetermined fault threshold; receive a position output of the positionsensor indicative of at least one position of the displacement memberduring the duration; and effect a motor control action based on theduration and the at least one position.

EXAMPLE 2

The surgical instrument of Example 1, wherein the motor control actioncomprises a dynamic brake.

EXAMPLE 3

The surgical instrument of Example 1 through Example 2 wherein the motorcontrol action comprises retracting the displacement member.

EXAMPLE 4

The surgical instrument of Example 1 through Example 3, wherein themotor control action comprises changing velocity of the motor.

EXAMPLE 5

The surgical instrument of Example 1 through Example 4, furthercomprising a timer circuit coupled to the control circuit, wherein thetimer circuit is configured to measure the duration.

EXAMPLE 6

The surgical instrument of Example 1 through Example 5, wherein thecontrol circuit is configured to effect the motor control action whenthe duration is equal to or exceeds a predetermined time period.

EXAMPLE 7

The surgical instrument of Example 6, wherein the predetermined timeperiod is a first predetermined time period, wherein the control circuitis configured to effect the motor control action when the time period isless than the first predetermined time period but greater than a secondpredetermined time period, and when the at least one position is in apredetermined zone along the distance.

EXAMPLE 8

The surgical instrument of Example 1 through Example 7, furthercomprising and end effector coupled to the displacement member.

EXAMPLE 9

The surgical instrument of Example 8, wherein the end effector comprisesa staple cartridge housing a plurality of staples, and whereintranslation of the displacement member causes the staples to be deployedform the staple cartridge.

EXAMPLE 10

A surgical instrument, comprising: a displacement member; a motorcoupled to the displacement member; a current sensor coupled to themotor, the current sensor configured to measure current drawn by themotor while translating the displacement member; a position sensor; anda control circuit coupled to the motor, the current sensor, and theposition sensor, wherein the control circuit is configured to: determinea duration during which the current drawn by the motor is maintained ator above a predetermined fault threshold; receive a position output ofthe position sensor indicative of at least one position of thedisplacement member during the duration; and effect a motor controlaction based on the duration and the at least one position.

EXAMPLE 11

The surgical instrument of Example 10, wherein the motor control actioncomprises a dynamic brake.

EXAMPLE 12

The surgical instrument of Example 10 through Example 11, wherein themotor control action comprises retracting the displacement member.

EXAMPLE 13

The surgical instrument of Example 10 through Example 12, wherein themotor control action comprises changing velocity of the motor.

EXAMPLE 14

The surgical instrument of Example 10 through Example 13, furthercomprising a timer circuit coupled to the control circuit, wherein thetimer circuit is configured to measure the duration.

EXAMPLE 15

The surgical instrument of Example 10 through Example 14, wherein thecontrol circuit is configured to effect the motor control action whenthe duration is equal to or exceeds a predetermined time period.

EXAMPLE 16

The surgical instrument of Example 15, wherein the predetermined timeperiod is a first predetermined time period, wherein the control circuitis configured to effect the motor control action when the duration isless than the first predetermined time period but greater than a secondpredetermined time period, and when the at least one position is in apredetermined zone along the distance.

EXAMPLE 17

The surgical instrument of Example 10 through Example 16, furthercomprising an end effector coupled to the displacement member.

EXAMPLE 18

The surgical instrument of Example 17, wherein the end effectorcomprises a staple cartridge housing a plurality of staples, and whereintranslation of the displacement member causes the staples to be deployedform the staple cartridge.

EXAMPLE 19

A method of controlling a motor in a surgical instrument, the surgicalinstrument comprising a displacement member, a motor coupled todisplacement member, the motor operable to translate the displacementmember, a control circuit coupled to the motor, a parameter sensorcoupled to the control circuit, and a position sensor coupled to thecontrol circuit, the method comprising: receiving, by the controlcircuit, a parameter output of the parameter sensor indicative of aforce applied to translate the displacement member; determining, by thecontrol circuit, a duration during which the parameter output ismaintained at or above a predetermined fault threshold; receiving, bythe control circuit, a position output of the position sensor indicativeof at least one position of the displacement member during the duration;and effecting, by the control circuit, a motor control action based onthe duration and the at least one position.

EXAMPLE 20

The method of Example 19, further comprising dynamically braking themotor by the control circuit.

EXAMPLE 21

The method of Example 19 through Example 20, further comprisingretracting the displacement member by the control circuit.

EXAMPLE 22

The method of Example 19 through Example 21, further comprising changingvelocity of the motor by the control circuit.

EXAMPLE 23

The method of Example 19 through Example 22, further comprising a timercircuit coupled to the control circuit, the method comprising measuringthe duration by the timer circuit.

EXAMPLE 24

The method of Example 19 through Example 23, further comprisingeffecting the motor control action when the duration is equal to orexceeds a predetermined time period.

EXAMPLE 25

The method of Example 24, wherein the predetermined time period is afirst predetermined time period, the method comprising effecting themotor control action when the time period is less than the firstpredetermined time period but greater than a second predetermined timeperiod, and when the at least one position is in a predetermined zonealong the distance.

EXAMPLE 26

A surgical instrument, comprising: a displacement member; a motorcoupled to the displacement member; a current sensor coupled to themotor, the current sensor configured to measure current drawn by themotor while translating the displacement member; a position sensor; anda control circuit coupled to the motor, the current sensor, and theposition sensor, wherein the control circuit is configured to: countdata points representing current (t) values at or above a predeterminedcurrent threshold; receive a position output of the position sensorindicative of at least one position of the displacement membercorresponding to at least one of the data points; and effect a motorcontrol action based on the number of data points counted and the atleast one position.

EXAMPLE 27

The surgical instrument of Example 26, wherein the motor control actioncomprises a dynamic brake.

EXAMPLE 28

The surgical instrument of Example 26 through Example 27, wherein themotor control action comprises retracting the displacement member.

EXAMPLE 29

The surgical instrument of Example 26 through Example 28, wherein themotor control action comprises changing velocity of the motor.

EXAMPLE 30

The surgical instrument of Example 26 through Example 29, furthercomprising a timer circuit coupled to the control circuit.

EXAMPLE 31

The surgical instrument of Example 26 through Example 30, wherein thecontrol circuit is configured to effect the motor control action if thecounted number of data points is equal to or exceeds a predeterminednumber.

EXAMPLE 32

The surgical instrument of Example 31, wherein the predetermined numberis a first predetermined number, wherein the control circuit isconfigured to effect the motor control action when the counted number ofdata points is less than the first predetermined number but greater thana second predetermined number, and when the at least one position is ina predetermined zone along the distance.

EXAMPLE 33

The surgical instrument of Example 26 through Example 32, furthercomprising an end effector coupled to the displacement member.

EXAMPLE 34

The surgical instrument of Example 33, wherein the end effectorcomprises a staple cartridge housing a plurality of staples, and whereintranslation of the displacement member causes the staples to be deployedform the staple cartridge.

The invention claimed is:
 1. A surgical instrument, comprising: an endeffector comprising a staple cartridge housing a plurality of staples; adisplacement member movable between an unfired position and a firedposition, wherein a translation of the displacement member toward thefired position causes the plurality of staples to be deployed from thestaple cartridge into tissue grasped by the end effector; a motorcoupled to displacement member, the motor operable to translate thedisplacement member between the unfired position and the fired position;a control circuit coupled to the motor; a parameter sensor coupled tothe control circuit; and a position sensor coupled to the controlcircuit, wherein the control circuit is configured to: receive aparameter output of the parameter sensor indicative of a force appliedto translate the displacement member; determine a duration during whichthe parameter output is maintained at or above a predetermined faultthreshold as the displacement member moves toward the fired position;receive a position output of the position sensor indicative of at leastone position of the displacement member during the duration; and effecta motor control action based on the duration and the at least oneposition.
 2. The surgical instrument of claim 1, wherein the motorcontrol action comprises a dynamic brake.
 3. The surgical instrument ofclaim 1, wherein the motor control action comprises retracting thedisplacement member.
 4. The surgical instrument of claim 1, wherein themotor control action comprises changing velocity of the motor.
 5. Thesurgical instrument of claim 1, further comprising a timer circuitcoupled to the control circuit, wherein the timer circuit is configuredto measure the duration.
 6. The surgical instrument of claim 1, whereinthe control circuit is configured to effect the motor control actionwhen the duration is equal to or exceeds a predetermined time period. 7.The surgical instrument of claim 6, wherein the predetermined timeperiod is a first predetermined time period, wherein the control circuitis configured to effect the motor control action when the duration isless than the first predetermined time period but greater than a secondpredetermined time period, and when the at least one position is in apredetermined zone along a distance.
 8. A surgical instrument,comprising: an end effector configured to effect a tissue treatment, theend effector comprising: a first jaw; and a second jaw movable relativeto the first jaw from an open position to a closed position to grasptissue therebetween; a displacement member movable between a startingposition and an ending position, wherein the second jaw is movabletoward the closed position based on the displacement member movingtoward the ending position; a motor coupled to displacement member, themotor operable to translate the displacement member between the startingposition and the ending position; a control circuit coupled to themotor; a parameter sensor coupled to the control circuit; and a positionsensor coupled to the control circuit, wherein the control circuit isconfigured to: receive a parameter output of the parameter sensorindicative of a force applied to translate the displacement member;measure a duration during which the parameter output is maintained at orabove a predetermined fault threshold as the displacement member movestoward the ending position; receive a position output of the positionsensor indicative of at least one position of the displacement memberduring the duration; and effect a motor control action based on theduration and the at least one position.
 9. The surgical instrument ofclaim 8, wherein the motor control action comprises a dynamic brake. 10.The surgical instrument of claim 8, wherein the motor control actioncomprises retracting the displacement member.
 11. The surgicalinstrument of claim 8, wherein the motor control action compriseschanging velocity of the motor.
 12. The surgical instrument of claim 8,further comprising a timer circuit coupled to the control circuit,wherein the timer circuit is configured to measure the duration.
 13. Thesurgical instrument of claim 8, wherein the control circuit isconfigured to effect the motor control action when the duration is equalto or exceeds a predetermined time period.
 14. The surgical instrumentof claim 13, wherein the predetermined time period is a firstpredetermined time period, wherein the control circuit is configured toeffect the motor control action when the duration is less than the firstpredetermined time period but greater than a second predetermined timeperiod, and when the at least one position is in a predetermined zonealong a distance.
 15. The surgical instrument of claim 8, wherein theend effector comprises a staple cartridge housing a plurality ofstaples, and wherein translation of the displacement member causes thestaples to be deployed form the staple cartridge.
 16. A surgicalinstrument, comprising: an end effector configured to effect a tissuetreatment, the end effector comprising: a first jaw; and a second jawmovable relative to the first jaw between an open position and a closedposition to grasp tissue; a displacement member; a motor coupled todisplacement member, the motor operable to translate the displacementmember through a plurality of predetermined zones, wherein the secondjaw is movable toward the closed position based on the displacementmember moving through the plurality of predetermined zones; a controlcircuit coupled to the motor; a parameter sensor coupled to the controlcircuit; and a position sensor coupled to the control circuit, whereinthe control circuit is configured to: receive a parameter output of theparameter sensor indicative of a force applied to translate thedisplacement member; determine a duration during which the parameteroutput is maintained at or above a predetermined fault threshold;receive a position output of the position sensor indicative of at leastone predetermined zone of the plurality of predetermined zones that thedisplacement member is positioned in during the determined duration; andeffect a motor control action based on the duration and the positionoutput.
 17. The surgical instrument of claim 16, wherein the pluralityof predetermined zones comprises six predetermined zones.